Shipping and installation for heating, ventilation, and air conditioning (HVAC)

ABSTRACT

A zone-control unit adapted for facile inclusion in a building&#39;s ductwork includes a mechanical terminal unit, inlet and outlet piping assemblies that are mechanically coupled together. The structure also includes at least one handle so the zone-control unit may be conveniently and safely handled both during shipping, and during installation into a HVAC system. Prior to installation into a HVAC system the fully-functional zone-control unit also includes a pair of caps respectively sealing the ends of the piping assemblies, and a pressure gauge for sensing pressurization of the piping assemblies and coil which the caps seal. Sealed in this way a pressure gauge permits testing to assure that the piping assemblies and coil are leak free, and readily assessing that zone-control units remain leak free until they are about to be installed into a building&#39;s HVAC system.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.11/429,418, entitled SHIPPING AND INSTALLATION FOR HEATING, VENTILATION,AND AIR CONDITIONING (HVAC), filed May 5, 2006. This application claimspriority to U.S. Patent Application Nos. 60/678,695 filed May 6, 2005and 60/755,976 filed Jan. 3, 2006. This application is also related toU.S. patent application Ser. No. 11/180,310 filed Jul. 12, 2005, whichis a continuation of U.S. Pat. No. 6,951,324; and to U.S. patentapplication Ser. No. 10/857,211 filed May 24, 2004; and to U.S. patentapplication Ser. No. 10/860,573 filed Jun. 2, 2004. This application isalso related to U.S. patent application Ser. No. 10/092,933 filed Sep.11, 2003. The entire contents of each of these applications and theirpriority filings are incorporated herein by reference for all purposes.

STATEMENT AS TO RIGHTS TO INVENTIONS MADE UNDER FEDERALLY SPONSOREDRESEARCH OR DEVELOPMENT

NOT APPLICABLE

REFERENCE TO A “SEQUENCE LISTING,” A TABLE, OR A COMPUTER PROGRAMLISTING APPENDIX SUBMITTED ON A COMPACT DISK

NOT APPLICABLE

BACKGROUND OF THE INVENTION

The present disclosure relates to methods, systems and apparatuses forbuilding heating, ventilation, and air conditioning (“HVAC”) systemsand, more particularly to assembly, verification, and maintenance of afully functional terminal unit, or a functionally equivalent devicecalled a lab valve damper when installed in certain environments.

In general, HVAC systems control the temperature and humidity of indoorair. In most HVAC systems, air is drawn in, filtered, cooled anddehumidified or heated and humidified, and then delivered to an airconditioned space. The greatest portion of incoming air is drawn fromthe air conditioned space for recirculation through the HVAC system.HVAC system includes fans and ductwork for moving conditioned air towhere it is needed while passing it through cooling and/or a heatingsections of the ductwork.

One risk which should be addressed in designing and operating HVACsystems is that of biological contamination by bacteria, molds, andviruses. In recent years, biological problems in indoor environmentshave received considerable attention. Most frequently, molds, bacteriaand/or virus grow wherever water collects in a HVAC systems ductwork,such as at its cooling sections.

Poor indoor air quality (“IAQ”) and the spread of infectious diseasethrough a HVAC system, at a minimum, can reduce worker productivity andincrease absenteeism. Even more alarming is the potential liability forillnesses suffered by workers due to poor IAQ. The Legionnaires' diseaseoutbreak in Philadelphia in 1976, is probably the most publicizedinstance of illness caused by poor IAQ. Even if contamination by moldsand bacteria doesn't affect workers, their growth within HVAC systemequipment creates maintenance problems which are very costly to correct.Left uncorrected, these problems exacerbate and, at a minimum,eventually reduce system's heat transfer efficiency.

HVAC systems in residential, commercial, education and researchbuildings usually include metallic pipes, hollow composite materialssuch as tubes, and the like. The systems are typically supported fromand between floor or ceiling joists. The HVAC system typically includesa primary or main duct. A series of smaller branch ducts which extendfrom the main duct are mounted between adjacent floor or ceiling joists.Such main and branch ducts are normally supported by metal hangerslocated between the joists. Often the branch ducts include pipes andconduit lines for transporting liquid or gas which are suspended fromceiling joists or an adjacent wall typically with Unistrut®, threadedrod, couplings, and various hanger brackets.

Piping and conduits that supply gas and/or liquids within buildingsbenefit from careful preparation. Builders or contractors typically useladders or scaffolding to reach areas where piping is routed soinstallation may be cumbersome. Occasionally the pipe or conduits areprepared on the ground and installed by ladder as more completeassemblies. Pipe and conduit assemblies prepared on the ground or afloor of a building under construction are more unwieldy than theunassembled components, but pre-assembly is often more practical.Furthermore, conditions existing at construction sites and the number ofdiffering types of components used in assembling a HVAC system rendercataloging known HVAC components a challenge.

Generically, a terminal unit, also sometimes referred to as an airhandling unit, is a HVAC system component that is located near an airconditioned space that regulates the temperature and/or volume of airsupplied to the space. When providing air to a more critical environmentsuch as a laboratory, an almost identical ductwork section is frequentlyreferred to as a lab valve damper rather than as a terminal unit, withthe distinction generally relating to the precision with which the unitcontrols the temperature and humidity of conditioned air. As usedthroughout this document, the phrase terminal unit encompasses either aterminal unit or a lab valve damper.

A HVAC system may be assembled using any one of several different typesof terminal units. Generally, the mechanical portion of a terminal unitincludes a casing through which air flows during operation of a HVACsystem. Accordingly, the casing includes an inlet for receiving air fromductwork of a HVAC system, and an outlet for supplying air to a space ina building. Casings are usually fabricated from 22 gauge galvanizedsheet steel. Due to the use of such light material, casings are easilydamaged during shipping to a building site and during installation intothe HVAC system. Those familiar with such damage to terminal unitcasings frequently refer to it as “oil canning” because it resembles howa light gauge oil can collapses as the liquid flows out.

In a typical hydronic (all-water) HVAC system, the mechanical portion ofa terminal unit includes a heat exchanging coil. Heated and/or cooledwater is pumped from a central plant through pipes to the coil. Air fromthe HVAC system's ductwork passes through the coil after entering andbefore leaving the casing. Usually, a single terminal unit is dedicatedfor heating and/or cooling each air conditioned space. Air from the ductconnected to the terminal unit passes through the coil to be heatedand/or cooled by water flowing through the coil before the air entersthe air conditioned space.

A Variable Air Volume (“VAV”) HVAC system, in response to a controlsignal from a thermostat or room sensor, supplies only that volume ofhot and/or cold air to an air conditioned space needed to satisfy thespace's thermal load. A VAV HVAC system meets changing cooling and/orheating requirements by adjusting the amount, rather than thetemperature, of air that flows to a space. For most buildings, a VAVHVAC system yields the best combination of comfort, first cost, and lifecycle cost.

A VAV terminal unit is a relatively complex assembly which includessheet metal, plumbing, electrical and pneumatic components. For example,a VAV terminal unit includes an airflow sensor that senses the velocityof air entering the terminal unit. To adjust the volume of cold air, aVAV terminal unit frequently includes a damper which automatically opensand closes as needed.

As a space's thermal load decreases, the damper starts closing therebyreducing the amount of heated or cooled air supplied to the space.Alternatively, the volume of air entering a space may be controlled byvarying the speed of a fan included in the terminal unit. For eithertype of VAV terminal unit, VAV HVAC systems save energy consumed by fansin comparison with alternative HVAC systems by continually adjustingairflow to the heating and/or cooling required.

To be operable and fully-functional, terminal units for a hydronic HVACsystem often include a coil, ductwork for supplying air to the coil andreceiving air from the coil, plumbing for supplying water into andreceiving water from the coil, and a control valve for regulating theamount of water flowing through the coil.

To match the flow of air through the terminal unit's ductwork to theprofile of the coil, the terminal unit's ductwork may include transitionsections both for air entering the coil and for air leaving the coil. Inaddition, a terminal unit may also include a re-heat coil, and/or asound attenuator. In a terminal unit adapted for use in a VAV HVACsystem, the terminal unit's ductwork may also include a damper and adamper actuator or variable speed fan for controlling the volume of airsupplied by the terminal unit, and an airflow sensor for sensing thevolume of air passing through the terminal unit.

Usually, all of the various parts needed to assemble a fully-functionalVAV HVAC system's terminal unit arrive at building construction sites asseparate components. Generally, these components are then assembled intoa fully functional terminal unit at the construction site. Due tocluttered working conditions usually existing at a construction sitewhere workers skilled in different crafts, e.g. plumbing, electrical,structural, etc., must concurrently collaborate to complete the buildingproject, assembling the various components into a fully functionalterminal unit may occupy the better part of a day. Furthermore, presentpractices and equipment are poorly adapted for swiftly constructing ahigh quality HVAC system that is easily commissioned.

For example, because it is less expensive to wire a HVAC system'sterminal units with 24 volt low voltage electrical power rather than 220or 110 volt power, presently sections of buildings include transformertrees which an electrician generally assembles by installing multiplestep down transformers on an electrical panel. This technique permitswiring 220 or 110 volt electrical power to the transformer tree on eachpanel, with the 24 volt low voltage electrical power then being wiredindividually from a transformer on the panel over distances of five (5)to one hundred (100) feet to a terminal units for energizing its DirectDigital Control (“DDC”) controller, and 2 way or 3 way automatictemperature control (“ATC”) control valve.

Usually, terminal units are supported from a building using anglebrackets, straps, or thread rod. Usually these support devices areattached directly to the terminal unit. Terminal unit casings areusually made using 22 gauge sheet metal. Due to the use of this lightmaterial, casings are easily dented or bent during installation.

With current construction site labor costing up to $80.00/hour or more,assembling a terminal unit at a construction site may cost $500.00 to$1,000.00 for labor alone. Furthermore, terminal units assembled at aconstruction site generally differ from one another due to assembly bydifferent craftsmen, and insufficient use of identical components inassembling each terminal unit. Due to conditions existing atconstruction sites and the number of differing types of components usedin assembling a HVAC system, cataloging the components used inassembling the system is impractical. Lastly, construction sitesgenerally lack any facilities for individually pre-testing buildingcomponents, such as terminal units, assembled on-site.

After assembling a HVAC system, it should be activated, tested andcommissioned to ensure IAQ. Testing a HVAC system only after it iscompletely assembled inevitably results in many hours of problem-solvingand leak-hunting. Usually, there are leaky joints, broken valves,damaged pipes, leaky coils and improperly assembled components that mustbe tracked down which further increases building costs. After finding afaulty component, it must be identified, ordered and replaced whichtakes time and delays completion of the building project. Furthermore,years after a building project is complete to maintain IAQ a buildingmanager responsible for the HVAC system's maintenance will often have toidentify and replace broken components.

The preceding considerations arising from construction site assembly offully functional terminal units slows construction, increase buildingcosts, requires rework when a terminal unit experiences an initialfailure, and ultimately makes more difficult and expensive maintaining abuilding's HVAC system years after those responsible for its assemblyare no longer available.

BRIEF SUMMARY OF THE INVENTION

An object is to provide improved HVAC devices, systems, and/or methods.Another object is to provide a zone-control unit for HVAC systems.Another object is to improve assembly of zone-control units for HVACsystems. Another object is to reduce the cost of zone-control units forHVAC systems. Another object is to reduce shipping and handling damageto HVAC system components. Another object is to provide modularcomponents for assembling HVAC systems. Another object is to permit jobsite storage of assembled zone-control units before their installationinto the HVAC system. Yet another object is to provide zone-controlunits for HVAC systems which are easier and simpler to install. Anotherobject is to increase the serviceability of zone-control units for HVACsystems. Another object is to permit cataloging components used inassembling HVAC systems. Another object is to increase theserviceability of zone-control units for HVAC systems. Yet anotherobject is to provide zone-control units for HVAC systems which may becommissioned more easily. Yet another object is to provide zone-controlunits for HVAC systems which are easier to maintain.

Advantageously, in some control system embodiments, dimensions of pipingcomponents are uniform regardless of the size of the heat exchanger.These may be a function of dimensional considerations and performanceparameters. For example, different heat exchangers may have differentface areas. The face area and the amount of heat exchanger surface candetermine the British Thermal Units per Hour (BTUH) output for aparticular heat exchanger. Often, current systems include piping andother components associated with heat exchangers that vary in size,dimension, and uniformity on a job site. Embodiments described hereinallow for uniformity of portable piping structures. This can alsofacilitate cataloguing of the system or product, including detailedparts lists, dimensional and electrical drawings, and the like. Thereare also substantial manufacturing, technical, and financial advantagesto such uniformity or standardization. Cataloguing and pre-manufacturinga control system with a portable piping structure allows for additionalfunctionality to be added on at the factory thus further enhancing theproduct.

Advantageously, embodiments disclosed herein provide energy efficientcontrol systems for maintaining room and other zone parameters to tighttolerances. Such systems can be configured to constantly adjustoperational parameters so as to maintain a room setpoint. Systems andcomponents thereof can be calibrated and programmed at the factory withbaseline parameters, which can allow for building automation systems,front end computers, and software applications to adjust parametersautomatically. Time frame and tolerance of adjustments can be a functionof algorithms and programs written in the software. Trouble shooting canbe done via readout at a thermostat or remotely via a wireless PDA.

According to one embodiment of the present invention, a fully-functionalzone-control unit is adapted for facile inclusion in ductwork of abuilding's hydronic HVAC system. The fully-functional zone-control unitincludes a conventional mechanical terminal unit through which air flowsduring operation of a HVAC system. The mechanical terminal unit includesa casing having an inlet for receiving air from ductwork of a HVACsystem, and an outlet for supplying air to a space in a building. Themechanical terminal unit includes a coil through which air from ductworkpasses upon entering the casing and before leaving the casing.

According to one embodiment of the present invention, the zone-controlunit also includes an inlet piping assembly that is connected to thecoil of the mechanical terminal unit. The inlet piping assembly has anend, separated from the connection to the coil, which is adapted forreceiving water from the HVAC system's plumbing which the inlet pipingassembly supplies to the coil. The fully-functional zone-control unitalso includes an outlet piping assembly that is connected to the coil ofthe mechanical terminal unit for receiving water therefrom. The outletpiping assembly has an end, separated from the connection to the coil,which is adapted for supplying water, received from the coil, to theHVAC system's plumbing. The fully-functional zone-control unit furtherincludes a structure that mechanically couples together the mechanicalterminal unit, the inlet piping assembly, and the outlet pipingassembly. The structure also includes at least one handle so thefully-functional zone-control unit may be conveniently and safelyhandled both during shipping, and during installation into a HVACsystem.

In another embodiment of the fully-functional zone-control unit, theinlet and outlet piping assemblies respectively pass through a pair ofholes that pierce each of the handles. Furthermore, each of the handlesincludes a pair of grommets respectively installed in each of the holeswhich fit snugly around the piping assemblies where they pass throughthe handles.

In another embodiment, prior to installation into a HVAC system thefully-functional zone-control unit also includes a pair of capsrespectively sealing the ends of the piping assemblies, and a pressuregauge for sensing pressurization of the piping assemblies and coil whichthe caps seal. Sealing the piping assemblies and coil and connecting apressure gauge permits testing them to assure that there are no leaks,and readily assessing that fully-functional zone-control units remainleak free until they are about to be installed into a building's HVACsystem.

In one aspect, the present invention provides a zone-control unitadapted for inclusion in ductwork of a hydronic heating, ventilation,and air conditioning (“HVAC”) system of a building. The zone-controlunit may include a mechanical terminal unit through which air flowsduring operation of a HVAC system. The mechanical terminal unit mayinclude a casing having an inlet for receiving air from ductwork of aHVAC system, and an outlet for supplying air to a space in a building.The mechanical terminal unit may also include a coil through which airfrom ductwork passes upon entering the casing and before leaving thecasing. The zone-control unit may also include an inlet piping assemblythat is connected to the coil of the mechanical terminal unit, and hasan end, separated from the connection to the coil, which is adapted forreceiving water from plumbing of the HVAC system which the inlet pipingassembly supplies to the coil. The zone-control unit may also include anoutlet piping assembly that is connected to the coil of the mechanicalterminal unit for receiving water therefrom, and an end, separated fromthe connection to the coil, which is adapted for supplying water,received from the coil, to plumbing of the HVAC system. The zone-controlunit may also include a structure, having at least one handle, thatmechanically couples together the mechanical terminal unit, the inletpiping assembly, and the outlet piping assembly, such that thezone-control unit may be conveniently and safely handled both duringshipping, and installation into a HVAC system.

In some aspects, the casing of the mechanical terminal unit may includea damper assembly for controlling air which flows through the casing.The zone-control unit may also include a controller for controllingoperation of the damper assembly. The controller may be a Direct DigitalControl (“DDC”) controller. The zone-control unit may also include alength of Local Area Network (“LAN”) cable that is coupled to the DDCcontroller for connecting the DDC controller to a LAN. In some cases,the zone-control unit may also include a length of electrical wire thatis coupled to the DDC controller for connecting the DDC controller to atemperature sensor. In related aspects, the combined inlet and outletpiping assemblies of the zone-control unit may include an automatictemperature control (“ATC”) control valve, and an electrical signalsupplied to the ATC control valve from the DDC controller can energizeoperation of the ATC control valve.

In another aspect, the casing of the mechanical terminal unit mayinclude a variable speed fan for controlling air which flows through thecasing. In some aspects, the structure that mechanically couplestogether the mechanical terminal unit, the inlet piping assembly and theoutlet piping assembly can include a plate that is pierced by a pair ofapertures through which the inlet piping assembly and the outlet pipingassembly respectively pass. An aperture piercing the plate may receive agrommet, such that a first grommet is received into a first of theapertures and fitted snugly around the inlet piping assembly where theinlet piping assembly passes through the plate, and a second grommet isreceived into a second of the apertures and fitted snugly around theoutlet piping assembly where the outlet piping assembly passes throughthe plate. The plate may also be pierced by another aperture whichadapts the structure for providing convenient and safe handling of thezone-control unit. The zone-control unit may also include a cradle thatbecomes disposed beneath the mechanical terminal unit, the inlet pipingassembly and the outlet piping assembly when the zone-control unit isinstalled in a HVAC system. The structure that mechanically couplestogether the mechanical terminal unit, the inlet piping assembly and theoutlet piping assembly can also include a sleeve mounting bracket whichsurrounds the casing of the mechanical terminal unit, and the plate maybe coupled to the mechanical terminal unit by being fastened to thesleeve mounting bracket. Relatedly, the sleeve mounting bracket mayinclude at least one hanging plate adapted for suspending thezone-control unit when the zone-control unit is installed in a HVACsystem. In some aspects, a sleeve mounting bracket surrounding thecasing of the mechanical terminal unit may include at least a portion ofa hanger that is adapted for suspending the zone-control unit when thezone-control unit is installed in a HVAC system. In some aspects, thestructure that mechanically couples together the mechanical terminalunit, the inlet piping assembly and the outlet piping assembly may alsoinclude a columnar mounting bracket which is secured to the casing ofthe mechanical terminal unit, and the plate may be coupled to themechanical terminal unit by being fastened to the columnar mountingbracket. The columnar mounting bracket may include a hanging plateadapted for suspending the zone-control unit when the zone-control unitis installed in a HVAC system. In some cases, a plate included in thestructure that mechanically couples together the mechanical terminalunit, the inlet piping assembly and the outlet piping assembly may besecured to the cradle. The cradle may be pierced by an aperture forproviding convenient and safe handling of the zone-control unit.

In another aspect, the zone-control unit may include a shield forprotecting tubes of the coil from damage during shipping and duringinstallation into a HVAC system. In some aspects, the zone-control unitmay include a pair of caps respectively sealing ends of the inlet pipingassembly and of the outlet piping assembly, and a pressure gauge forsensing pressurization of the inlet piping assembly, coil and outletpiping assembly which the caps seal. The zone-control unit may alsoinclude a pair of flexible hoses respectively connected to ends of theinlet piping assembly and of the outlet piping assembly for facilitatingcoupling the inlet piping assembly and outlet piping assembly toplumbing of the HVAC system which supplies water to and receives waterfrom the coil of the zone-control unit. Similarly, the zone-control unitmay include a pair of valves which are respectively connected to ends ofthe flexible hoses disposed away from the ends of the inlet pipingassembly and of the outlet piping assembly to which the flexible hosesconnect, and a pressure gauge for sensing pressurization of the inletpiping assembly, coil and outlet piping assembly which may be sealed bythe valves. The zone-control unit may also include a pair of tees whichare respectively connected to each of the valves furthest from ends ofthe flexible hoses to which the valves connect.

In one embodiment, the zone-control unit of the present inventionincludes identifying tags attached to components of inlet and outletpiping assemblies that are likely to eventually require replacement. Thezone-control unit may also have an enclosure which contains componentsof the zone-control unit. Relatedly, components of the zone-control unitcontained within the enclosure may include a transformer and a DDCcontroller. The enclosure may protect the components from environmentalhazards such as falling dirt, rain, sleet, snow, windblown dust,splashing water, hose-directed water and internal explosions. Further,the zone-control unit may include a length of LAN cable that is coupledto the DDC controller for connecting the DDC controller to a LAN. Insome aspects, the zone-control unit may include a length of electricalwire that is coupled to the DDC controller for connecting the DDCcontroller to a temperature sensor. Combined inlet and outlet pipingassemblies of the zone-control unit may include an ATC control valve,and an electrical signal supplied to the ATC control valve from the DDCcontroller may energize operation of the ATC control valve. Thezone-control unit may also include a service lamp adapted forfacilitating inspection of the zone-control unit. In some aspects, thezone-control unit may include a switched power outlet adapted forproviding a source of electrical power at the zone-control unit for usewhen servicing the zone-control unit.

In another aspect, the present invention provides a unit for inclusionin a heating, ventilation, and air conditioning (“HVAC”) system of abuilding, where the HVAC system includes a coil. The unit may include aninlet piping assembly having a first end adapted for connection to thecoil and a second end for receiving fluid for the coil, an outlet pipingassembly having a first end adapted for connection to the coil and asecond end for fluid flowing from the coil, a control valve disposedalong the inlet piping of the outlet piping, the control valve operablein response to an electrical signal, and a shipping and installationstructure supporting the inlet piping, the outlet piping, and thecontrol valve with relative positions appropriate for use in the HVACsystem. In another aspect, the unit may include a mechanical terminalunit having ductwork for transmitting air therethrough and a coil inthermal communication with the air passing through the ductwork, aninlet piping assembly having a first end connected to the coil and asealed second end, an outlet piping assembly having a first end adaptedconnected to the coil and a sealed second end, a fluid disposed along asealed fluid path between the sealed end of the inlet piping and thesealed end of the outlet piping, the fluid having a pressure, a shippingand installation structure supporting the inlet piping, the outletpiping, and the mechanical terminal unit, and a pressure gauge along thesealed fluid path and supported by the structure so as to indicate thepressure and verify sealing of the sealed fluid path before and aftershipping.

In one aspect, the present invention provides a zone-control unit foruse in a heating, ventilation, and air conditioning (HVAC) system. Thezone-control unit can include a casing, a coil disposed within thecasing, an inlet piping assembly coupled with the coil for supplyingliquid or gas to the coil, an outlet piping assembly coupled with thecoil for receiving liquid or gas from the coil, a handle that maintainsthe casing, the inlet piping assembly, and the outlet piping assembly inpositional relationship. The unit can also include a damper assemblycontroller coupled with the casing, where the damper assembly controlleris configured to receive a signal from a thermostat or a room sensor. Insome aspects, the damper assembly controller can include a directdigital control (DDC) controller. Relatedly, the damper assemblycontroller can be equipped with Local Area Network (LAN) communicationcapability. In some aspects, the zone-control unit can include anautomatic temperature control (ATC) valve configured to receive a signalfrom the damper assembly controller. The zone-control unit may alsoinclude an enclosure, where the ATC valve and at least a portion of thehandle are disposed within the enclosure, such that the handle isaccessible for transportation or shipping. The damper assemblycontroller may be coupled with an on-off switch, a transformer, or both.Relatedly, the damper assembly may be coupled with a transformer, andthe transformer can be coupled with a 110 volt cord having a male plug.In another aspect, the zone-control unit can include a housing, wherethe damper assembly controller is disposed within the housing. Thezone-control unit may also include a variable speed fan disposed withinthe casing. In some instances, the zone-control unit may include acradle coupled with the handle. The unit may also include a sleevemounting bracket coupled with the casing. In a related aspect, at leastone of the coil, the inlet piping assembly, or the outlet pipingassembly may be coupled with a pressure gauge, a drain, or a vent. Theinlet piping assembly and the outlet piping assembly may be sealed, andthe coil, the inlet piping assembly, and the outlet piping assembly maybe pressurized. In some instances, the inlet piping assembly may becoupled with an inlet hose by a inlet fitting, and the outlet pipingassembly may be coupled with an outlet hose by a outlet fitting.

In still another aspect, a zone-control unit of the present inventionmay include a thermal transfer assembly having a supply port and areturn port, an inlet piping assembly having a first passage coupledwith the thermal transfer assembly supply port and a second passagecoupleable with an upstream fluid source, an outlet piping assemblyhaving a first passage coupled with the thermal transfer assembly returnport and a second passage coupleable with a downstream fluiddestination, a duct interface, and a bracket supporting the ductinterface, the inlet piping assembly, and the outlet piping assemblywith relative positions appropriate for use in the climate controlsystem. In some aspects, the inlet piping assembly second passage andthe outlet piping assembly second passage may each be sealed, the inletpiping assembly first passage may be in sealed communication with thethermal transfer assembly supply port, and the outlet piping assemblyfirst passage may be in sealed communication with the thermal transferassembly return port. Relatedly, the thermal transfer unit may contain avacuum, a non-pressurized fluid, or a pressurized fluid. In someaspects, the unit may further include a pressure gauge, and the pressuregauge may be coupled with the thermal transfer assembly, the inletpiping assembly, or the outlet piping assembly. The inlet pipingassembly may be coupled with a drain, a strainer, a pressure gauge, apressure/temperature port, or a supply shutoff valve. The outlet pipingassembly may be coupled with a control valve, a balancing valve, a vent,a pressure gauge, a pressure/temperature port, or a return shutoffvalve. In some aspects, the duct interface is coupleable with a duct ofthe HVAC system, such that the duct houses at least a portion of thethermal transfer unit. The zone-control unit may also include a bypasspiping assembly coupling the inlet piping assembly with the outletpiping assembly.

In another aspect according to the present invention, the zone-controlunit may comply with a standard such as a Leadership in Energy andEnvironmental Design (LEED) standard, an American Society of Heating,Refrigerating, and Air Conditioning Engineers (ASHRAE) standard, or abuilding code standard. In some aspects, the inlet piping second passageor the outlet piping second passage may be coupled with a hose via apress-fitting joint. Relatedly, the press-fitting joint may comply withan appropriate standard. In some aspects, the zone-control unit mayinclude a validation package, which may have a digital picture of thezone-control unit, a completed quality control sheet, an operations andmaintenance document, a parts list with model number, an Indoor AirQuality (IAQ) certification, or a piping, electrical, and controlsschematic.

In one aspect, the present invention provides a method of installing azone-control unit for use in an HVAC system. The method can includeengaging a handle of the zone-control unit, where the zone-control unitincludes a casing, a coil disposed within the casing, an inlet pipingassembly coupled with the coil for supplying liquid or gas to the coil,an outlet piping assembly coupled with the coil for receiving liquid orgas from the coil, a handle that maintains the casing, the inlet pipingassembly, and the outlet piping assembly in positional relationship, anda damper assembly controller coupled with the casing. The method canalso include maneuvering the handle so as to position the zone-controlunit in a desired location and orientation, coupling the inlet pipingassembly with piping of the HVAC system, and coupling the outlet pipingassembly with piping of the HVAC system.

In another aspect, the present invention provides a method of preparinga zone-control unit for delivery to a construction site for installationin a heating, ventilation, and air conditioning (HVAC) system. Themethod can include coupling a coil with an inlet piping assembly and anoutlet piping assembly, placing the coil within a casing, and coupling ahandle with the casing, the inlet piping assembly, and the outlet pipingassembly so as to maintain the casing, the inlet piping assembly, andthe outlet piping assembly in positional relationship. The method canalso include coupling a damper assembly controller with the casing,sealing the inlet piping assembly and the outlet piping assembly, andpressurizing the coil, the inlet piping assembly, and the outlet pipingassembly. In related aspects, the method may include testing the coil,the inlet piping assembly, and the outlet piping assembly for leaks. Themethod may also include wrapping the zone-control unit to reducecontamination. Such protection measures may include applying shrinkwrap, plastic wrap, or the like to the unit prior to shipping orinstallation, so as to provide a measure of protection from dust orother contaminants. In some aspects, the preparation is performed by aunion member selected from a group such as the United Association ofJourneymen and Apprentices of the Plumbing and Pipefitting Industry ofthe United States and Canada, a construction sheet metal union, and anelectrician's union, and/or at a facility or by a company certified orapproved by such a union.

In yet another aspect, the present invention provides a piping and coilassembly for transporting liquid or gas in a heating, ventilation, andair conditioning (HVAC) system. The piping and coil combination assemblycan include a coil, an inlet piping assembly coupled with the coil forsupplying liquid or gas to the coil, an outlet piping assembly coupledwith the coil for receiving liquid or gas from the coil, and a handlethat maintains the coil, the inlet piping assembly, and the outletpiping assembly in positional relationship.

The methods and apparatuses of the present invention may be provided inone or more kits for such use. For example, the kits may comprise asystem for use in an HVAC system. Optionally, such kits may furtherinclude any of the other system components described in relation to thepresent invention and any other materials or items relevant to thepresent invention. The instructions for use can set forth any of themethods as described herein. It is further understood that systemsaccording to the present invention may be configured to carry out any ofthe method steps described herein.

These and other features, objects and advantages will be understood orapparent to those of ordinary skill in the art from the followingdetailed description of the preferred embodiment as illustrated in thevarious drawing figures.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an fully-functional zone-control unitready for installation in a HVAC system which includes a zone-controlunit having a casing from which a pair of handles project for supportinginlet and outlet piping assemblies included in the fully-functionalzone-control unit, according to one embodiment of the present invention.

FIG. 2 is an elevational view of a plate that is included in the handlesillustrated in FIG. 1 which project from the zone-control unit's casingand support the piping assemblies, according to one embodiment of thepresent invention.

FIG. 3 is a perspective view of an alternative embodiment,fully-functional zone-control unit which includes a NEMA enclosure thatadapts the unit for installation outside a building, according to oneembodiment of the present invention.

FIG. 4 is a perspective view of the alternative embodiment,fully-functional zone-control unit of FIG. 3 that includes a shieldwhich protects coils included in the casing from mechanical damage,according to one embodiment of the present invention.

FIG. 5 is a perspective view of an alternative embodimentfully-functional zone-control unit similar to that depicted in FIG. 1,which includes a cradle located beneath the zone-control unit forsupporting inlet and outlet piping assemblies included in thefully-functional zone-control unit, according to one embodiment of thepresent invention.

FIG. 6 is a perspective view of an alternative embodimentfully-functional zone-control unit in accordance with the presentdisclosure, similar to that depicted in FIG. 1, which includes a pair ofsleeve mounting brackets that surround the casing, and support thezone-control unit when it is installed in a HVAC system.

FIG. 7 is an exploded perspective view of one of the zone-control unitmounting brackets depicted in FIG. 6.

FIG. 8 is an elevational view taken along a line 8-8 in FIG. 7.illustrating mating of a pair of handles included in the zone-controlunit mounting bracket depicted in FIGS. 6 and 7.

FIG. 9 is a perspective view of another alternative embodimentfully-functional zone-control unit in accordance with the presentdisclosure, similar to that depicted in FIG. 1, which includes fourcolumnar mounting brackets that are secured to the casing, and supportthe zone-control unit when it is installed in a HVAC system.

FIG. 10 is a perspective view of an electrical components enclosure foran fully-functional zone-control unit in accordance with the presentdisclosure adapted for use inside a building.

FIG. 11 is an elevational view of yet another alternative embodiment ofa fully-functional zone-control unit in accordance with the presentdisclosure, in which appears a portion of the zone-control unitappearing in FIG. 1, that includes flexible braided hoses whichfacilitate connecting the zone-control unit's inlet and outlet pipingassemblies to a building's plumbing.

FIGS. 12A and B illustrate a zone-control unit according to oneembodiment of the present invention.

FIGS. 13A and B illustrate a zone-control unit according to oneembodiment of the present invention.

FIGS. 14A and B illustrate a zone-control unit according to oneembodiment of the present invention.

FIG. 15 illustrates a zone-control unit according to one embodiment ofthe present invention.

FIG. 16 illustrates a zone-control unit according to one embodiment ofthe present invention.

FIG. 17 illustrates a zone-control unit according to one embodiment ofthe present invention.

FIGS. 18A-18E illustrate a heat exchanger/coil packaged with ancillarycomponents.

FIGS. 19A-19B illustrate differing HVAC units having standardizedcomponents, along with aspects of those components.

FIG. 20 illustrates interfacing of HVAC unit support structures, showingthat the support structures can be used to suspend and support the HVACunit for use in an HVAC system.

FIGS. 21A and 21B illustrate a quality control process and method forproviding HVAC units and assembling and HVAC system.

FIG. 22 shows a control assembly for an HVAC system.

FIG. 23 shows an embodiment of a zone control unit or heat exchangersmart control configuration.

FIG. 24 shows graph of a front and mathematical calculation or algorithmbased on desired performance and time values.

DETAILED DESCRIPTION OF THE INVENTION

The perspective view of FIG. 1 illustrates a fully-functional HVACterminal unit referred to by the general reference character 100. Thefully-functional zone-control unit 100 depicted in FIG. 1, whichillustrates one embodiment of the present invention, preferably includesa mechanical terminal unit 102 having a casing 104 visible in FIG. 1.The casing 104, which can be made from various materials of differingthicknesses, is frequently made from galvanized sheet steel material.Frequently, the casing 104 is lined with a thermal insulation material,not visible in FIG. 1, which may be chosen from various different typessuch as fiberglass insulation, rigid duct board fiber insulation,polyolefin, closed cell, foam insulation, etc. In some embodiments,insulation contained in zone-control unit 100 complies with an industrystandard, such as a standard set by the Office of Statewide Health andPlanning Department (OSHPOD).

For VAV zone-control units 100, the mechanical terminal unit 102preferably includes a damper assembly, not visible in FIG. 1. The damperassembly is supported for rotation within the casing 104 by a shaftwhich extends through and beyond the casing 104. The mechanical terminalunit 102 of a zone-control unit 100 that includes the damper assemblyalso includes a DDC controller 112 depicted in FIG. 3. The DDCcontroller 112 is coupled to a damper motor, not visible in any of thefigures, which rotates the damper assembly. The DDC controller 112receives a signal from a thermostat or room sensor and responsivethereto controls operation of the damper assembly to regulate the amountof heating or cooling provided by air leaving the zone-control unit 100.The DDC controller 112 may be selected from various different types suchas pneumatic, analog electronic or direct digital electronic. Themechanical terminal unit 102 also includes an airflow sensor, also notvisible in FIG. 1, which is usually located near an air inlet to thecasing 104 and may be selected from various types for sensing thevelocity of air entering the casing 104.

To heat or cool air flowing through the mechanical terminal unit 102,the casing 104 includes a coil 122 that is located near the air inletthereto, and which adapts the mechanical terminal unit 102 for inclusionin a hydronic HVAC system. The casing 104 includes both an inlet collar,not visible in FIG. 1, and an outlet connection 124 each of which isadapted to mate with a building's HVAC ductwork. If a zone-control unit100 were to be assembled at a construction site, the mechanical terminalunit 102 would arrive there with the various components listed abovemostly assembled, other than the DDC controller 112 and the dampermotor, by the terminal unit's manufacturer.

The mechanical terminal unit 102 is preferably selected from amongvarious different types and styles sold by Krueger based in Richardson,Tex. Krueger is a division of Air Systems Components (ASC) which is partof the Dayton, Ohio Air System Components Division of TomkinsIndustries, Inc. of London, England.

To fashion the mechanical terminal unit 102 into a zone-control unit 100ready for installation into a building's HVAC system, various plumbingcomponents must be added for circulating either hot or cold waterthrough the coil 122. For supplying water to the coil 122 thezone-control unit 100 includes an inlet piping assembly 202. The pipingassembly 202 includes an L-shaped section of pipe 204 which connects atone end to a lower header of the coil 122, not visible in FIG. 1. At itsother end, the pipe 204 ends at a union 208. The other half of the union208 connects to a tailpiece 212 which receives both apressure/temperature (“P/T”) port 214 and a drain 216. The drain 216includes a ball valve integrated ¾″ male garden hose end connection tofacilitate draining the coil 122 when maintenance or repairs becomenecessary. A ball valve 222, which includes a strainer, connects to aside of the tailpiece 212 away from the union 208 to permit stopping hotor cold water from circulating through the coil 122. An opposite side ofthe valve 222 from the tailpiece 212 receives a length of pipe 224 whichadapts the piping assembly 202 for connecting to a building's plumbing.

The zone-control unit 100 also includes an outlet piping assembly 232for receiving water from the coil 122. A short length of pipe 234 whichends in a tee 236 connects to an header 238 of the coil 122. A manualair vent 242 is connected to and projects upward above the tee 236 tofacilitate eliminating air from the piping assemblies 202, 232 followingfirst assembling the HVAC system, or reassembly of the zone-control unit100 when maintenance or repairs become necessary. An L-shaped section ofpipe 244 is connected to and depends below the tee 236. Similar to thepipe 204, an end of the pipe 244 furthest from the tee 236 ends at aunion 246. The other half of the union 246 connects to a 2 way or 3 wayATC control valve 252. The ATC control valve 252 may either be of a typedepicted in FIG. 1 that provides only on-off control, or be of a typethat provides proportional control, not illustrated in any of the FIGs.An electrical signal supplied to the ATC control valve 252 from the DDCcontroller 112 via a control signal cable 114 energize operation of theATC control valve 252.

A side of the ATC control valve 252 furthest from the union 246 connectsto a union 254. Connecting the ATC control valve 252 into the pipingassembly 232 on both sides with unions 246, 254 facilitates itsreplacement when maintenance or repairs become necessary. A tailpiece262, connected to the other side of the union 254 furthest from the ATCcontrol valve 252, receives both a P/T port 264 and a manual air vent266. The P/T ports 214 and 264 facilitate measuring pressure and/ortemperature of water circulating through the coil 122. The vent 266facilitates eliminating air from the piping assembly 232 following firstassembling the HVAC system, or reassembly of the zone-control unit 100when maintenance or repairs become necessary. A manual balancing valve272 connects to the other side of the tailpiece 262 from the furthestfrom the union 254. An opposite side of the valve 272 from the tailpiece262 receives a length of pipe 274 which, similar to the pipe 224, adaptsthe piping assembly 232 for connecting to a building's plumbing. Thevalves 222, 216, 272 and other plumbing fittings included in the pipingassemblies 202, 232 are preferably manufactured by HCI of MadisonHeights, Mich. The valves 222, 272 permit isolating from the building'splumbing, when maintenance or repairs become necessary, the coil 122 andthose portions of the piping assemblies 202, 232 which connect to thevalves 222, 272.

As described thus far, the zone-control unit 100 including the pipingassemblies 202, 232 are substantially the same as those which a skilledsheet metal worker, controls contractor, electrician, and pipe fittermight collectively assemble at a building site. However, in assemblingzone-control units 100 in accordance with the present invention for aparticular building project or significant portion thereof, all of thelengths of pipe, plumbing fittings, valves, vents, P/T ports, etc. arethe same. Consequently, when a repair become necessary a buildingmanager or the manager's personnel responsible for maintaining the HVACsystem may confidently order a replacement part knowing that it willsurely fit because the plumbing of each zone-control unit 100 is notunique. Rather, in accordance with the present invention the plumbing ofzone-control units 100 is uniform throughout the building or significantportion thereof. Furthermore, because plumbing of zone-control units 100is uniform throughout the building or significant portion thereof,acting either from prudence or caution a building manager mayconfidently maintain an inventory of plumbing components for thezone-control units 100 to have on hand when they need repair therebysignificantly reducing downtime while also maintaining IAQ.

In addition to being assembled with uniform plumbing, in accordance withthe present invention tags 282 are attached to each valve 252, 272 orother component that are likely to eventually require replacement. Afterthe HVAC system has been commissioned, when a failure occurs and islocated, the presence of an identifying tag 282 attached to a failedcomponent simplifies its replacement and reduces the time requiredtherefor. The tags 282 are particularly helpful if components fromdifferent manufacturers and/or different catalogs have been incorporatedinto the HVAC system. The tags 282 are preferably engraved plastic, butmay also be made from metal, paper, or any other appropriate material.The tags 282 may carry barcodes or plain language, for example, and maybe customized to provide information in the manner most useful for aparticular project. In accordance with the present invention,performance requirements for each zone-control unit 100 such as GPM,CFM, CV and so on are marked thereon in an accessible and well definedlocation.

Also in accordance with embodiments of the present invention, each pipe224, 274 is sealed by a spun copper cap 284 which is five (5) timesthicker than the pipe 224, 274, and the assembled piping assemblies 202,232 include a pressure gauge 286. Following fabrication and sealing ofthe piping assemblies 202, 232, they are pressure tested with, forexample, a gas such as air. Other gasses or a liquid may be used asappropriate for materials used in the piping assemblies 202, 232. Atypical pressure range used in testing assembled piping assemblies 202,232 and coil 122 is 20-400 psi, and in one embodiment is preferably 140psi. While pressurized, the piping assemblies 202, 232 and the coil 122are checked for leaks, e.g. with a soap solution. Any defects inassembly found during pressure testing are repaired and/or defectivecomponents replaced. For example, experience in assembling zone-controlunits 100 in accordance with embodiments of the present inventionindicates that about 3 to 7% of new coils 122 are defective and must bereplaced.

When inspection and pressure testing indicates that no leaks appear toexist in the piping assemblies 202, 232 and the coil 122, they are thensealed and re-pressurized to at least 100 psi, preferably 140 psi, orany other desired negative or positive pressure, including a vacuum.After pressurization, the piping assemblies 202, 232 and the coil 122remain sealed for 24 hours throughout which they must hold thepressurization to confirm that the zone-control unit 100 is undergoinginstallation into a HVAC system. After the piping assemblies 202, 232and the coil 122 pass this 24 hour quality assurance test, zone-controlunits 100 can be ready for shipping to a construction site. Inaccordance with one embodiment of the present invention, the pipingassemblies 202, 232 and coil 122 of zone-control units 100 ready forinstallation remain pressurized continuously after their 24 hour qualityassurance test at a pressure of at least 60 psi until they are about tobe installed into a building's HVAC system. In some cases, the shippingpressure can be 40 psi, or any other desired pressure.

Immediately before installing a zone-control unit 100 at a constructionsite, their readiness for installation can be confirmed by checking thepressure gauge 286. If the pressure gauge 286 fails to indicate aspecified pressure, then the zone-control unit 100 may need furthertesting and/or repair, and should not be installed into the HVAC system.Instead an identically assembled zone-control unit 100 having a pressuregauge 286 which indicates the specified pressure may be immediatelysubstituted for a defective one, and the defective zone-control unit 100may either be repaired and re-tested at the construction site, or it maybe returned to its vendor for repair.

Identifying and replacing faulty piping assemblies 202, 232 and/or coil122 in this way prior to installing the zone-control unit 100 saves timeand money. The present invention can eliminate an inability to test thepiping assemblies 202, 232 and coil 122 of each zone-control unit 100assembled at a construction site until the entire HVAC system iscompletely assembled and ready for commissioning. Off-site assembly andtesting of zone-control units 100, rather than assembling the componentsat the construction site, improves quality control by individuallyassuring that each zone-control unit 100 is ready for installation in aHVAC system. In this way the present invention saves time and money thatwould otherwise be spent tracking down leaks that occur usingtraditional on-site assembly of zone-control units 100. Furthermore, bypreventing pinhole leaks in the zone-control unit 100, which inevitablyresult in mold, biochemical hazards, etc., the present inventionsignificantly improves IAQ both initially and throughout the HVACsystem's service life. Relatedly, insulation can be applied to orincorporated into a zone-control unit or portable piping structure atthe factory, instead of in the field or at the job site. Thus, units orstructures can be made at the factory, pre-assembled, pre-calibrated,and pre-insulated, thus providing further cost savings and efficiencies.

One problem which arises with assembling zone-control units 100 at alocation remote from a construction site is that during theirtransportation to the site and during installation into a building'sductwork zone-control units 100 may be manipulated by the pipingassemblies 202, 232 and/or the coil 122 of the mechanical terminal unit102. Such handling of zone-control units 100 during installation maydamage seals between the components as well as the componentsthemselves. Furthermore, such damage may not be noticed until the HVACsystem is pressurized for commissioning or at a later date. At thattime, locating a leak or malfunctioning part may be time-consuming,virtually impossible and cost prohibitive. To reduce any possibilitythat a zone-control unit 100 might be damaged while being transportedfrom its assembly, test and qualification location to a constructionsite and to facilitate handling the zone-control unit 100 during itsinstallation into the HVAC system, in accordance with the embodiment ofthe present invention illustrated in FIG. 1 each zone-control unit 100also includes a pair of handles 502 that are preferably secured to thecasing 104 of the mechanical terminal unit 102 near opposite endsthereof.

Each of the handles 502 includes an L-shaped handle mounting bracket 504which is rigidly secured to a wall 132 of the mechanical terminal unit102 which is nearest to the piping assemblies 202, 232. As depicted inFIG. 1, the handle mounting brackets 504 are secured near opposite endsof the wall 132 of the zone-control unit's casing 104. Each of thehandles 502, for example illustrated in FIG. 2, is formed by a plate 506a of sheet metal. Each plate 506 a include a plurality of holes 508through which fasteners pass for securing the plate 506 a to a portionof the handle mounting bracket 504 that projects outward from the wall132. The handle mounting brackets 504 and the plates 506 a can be madefrom 12 gauge sheet steel. The handle mounting brackets 504 can begalvanized and the plates 506 a can be powder coated, and can be madefrom various materials and gauge sizes.

For use with the zone-control unit 100, each plate 506 a is also piercedby a rectangularly-shaped hole 512, and by a pair of circularly-shapedholes 514 illustrated with dashed lines in FIG. 2. The holes 512 arelarge enough to accept many lifting devices including human hands,forklift, Unistrut, pipe or other lifting device. Each hole 512 has acurved edge 518 to prevent hand injuries, and may lack any sharp edgesor non-rolled edges. The holes 514 each receive a grommet 522 that fitssnugly around the piping assemblies 202, 232 where they pass throughplates 506 a.

Arranged in this way, the handle mounting brackets 504 and plates 506 aprovide a structure for mechanically coupling the mechanical terminalunit 102 and the piping assemblies 202, 232 together thereby reducingany possibility that the zone-control unit 100 might be damaged whilebeing transported from its assembly, test and qualification location toa construction site. Furthermore, the handles 502 protect zone-controlunits 100 during shipping, and facilitate their handling duringinstallation into the HVAC system such as maneuvering zone-control units100 into position in a building's ductwork. During installation, thehandle mounting brackets 504 and plates 506 a maintain positionalrelation-ships between the mechanical terminal unit 102 including thecoil 122 and the piping assemblies 202, 232 because the handle mountingbrackets 504 and plates 506 a mechanically bind the entire zone-controlunit 100 together into a single unit.

In renovating existing buildings by adding an up-to-date HVAC system,sometimes there exists no interior space for installing zone-controlunits 100. To permit installing zone-control units 100 on a renovatedbuilding's roof where its components are exposed to environmentalhazards, an alternative embodiment of the zone-control unit 100,depicted in FIG. 3, includes a weatherproof NEMA enclosure 552. For thisalternative embodiment zone-control unit 100, all of the electricalcomponents together with their wiring are located within the NEMAenclosure 552, and outdoor grade conduit 554 encloses the cable 114 thatinterconnects the DDC controller 112 and the ATC control valve 252.Accordingly, in addition to the DDC controller 112, the NEMA enclosure552 also encloses a on-off switch 562 and a transformer 564 forsupplying 24 volt electrical power to the DDC controller 112.

Cooling for the components of the mechanical terminal unit 102 enclosedwithin the NEMA enclosure 552 may be provided by a mini-fan mountedwithin the NEMA enclosure 552. Alternatively, these components of themechanical terminal unit 102 may be cooled by air flowing through theHVAC system's ductwork. For example, one end of a small duct may beconnected into the plenum upstream from the coil 122 with the other endconnecting to the NEMA enclosure 552. The ATC control valve 252 may alsobe cooled by enclosing it and connecting its enclosure to the HVACsystem's plenum by a small duct. If the electrical wires connecting thecoil 122 to the ATC control valve 252 are enclosed within a one (1) inchdiameter outdoor grade conduit 554, cool air first supplied to the ATCcontrol valve 252 flows to the NEMA enclosure 552 through the outdoorgrade conduit 554.

The NEMA enclosure 552 may be selected from among NEMA Type 3R, 4 or 10enclosures. NEMA Type 3R, 4 or 10 enclosures all provide a degree ofprotection for personnel against incidental contact with equipmentenclosed therein. NEMA Type 3R enclosures are constructed for eitherindoor or outdoor use providing a degree of protection against fallingdirt, rain, sleet, and snow, and are undamaged by the external formationof ice on the enclosure. NEMA Type 4 enclosures are also constructed foreither indoor or outdoor use again providing a degree of protectionagainst falling dirt, rain, sleet, snow, windblown dust, splashingwater, and hose-directed water, and are also undamaged by the externalformation of ice on the enclosure. NEMA Type 10 enclosures are designedto contain an internal explosion without causing an external hazard,i.e. NEMA Type 10 enclosures meet the requirements of the Mine Safetyand Health Administration, 30 CFR, Part 18.

As described thus far, zone-control units 100 have exposed U-shapedportions 566 of tubes, best illustrated in FIG. 3, through which watercirculates that are located at the end of the coil 122 furthest from thepiping assemblies 202, 232. To reduce the possibility that the exposedU-shaped portions 566 of these tubes might be damaged either duringtransportation of the zone-control unit 100 and/or its installation intoa HVAC system, as illustrated in FIG. 4 an alternative embodiment of thezone-control unit 100 includes a shield 568 preferably made from sheetsteel material.

The shield 568 is secured to the coil 122 and perhaps also the casing104, and covers the U-shaped portions 566 of tubes included in the coil122. Though not illustrated in FIG. 4, the shield 568 may be lined withinsulation to further reduce heat loss from the U-shaped portions 566 ofthe coil 122 in addition to the heat loss reduction provided byinstalling an uninsulated shield 568.

FIG. 5 is a perspective view of an alternative embodiment zone-controlunit 100 in accordance with the present invention similar to thezone-control unit 100 depicted in FIG. 1. The zone-control unit 100depicted in FIG. 4 includes a rectangularly-shaped cradle 572 disposedbeneath and secured to the mechanical terminal unit 102. In theembodiment of the zone-control unit 100 depicted in FIG. 4, plates 506b, for mechanically securing the piping assemblies 202, 232 to thecasing 104, omit the handles 502 established by the holes 512 formed inthe plates 506 a. Instead the plates 506 b are narrower and L-shapedwith a foot 574 which is secured to the cradle 572. The cradle 572 ispierced by holes 576 respectively located near each of its four corners,only three of which are visible in FIG. 4. In one embodiment, threadedrods 578 respectively pass through each of the holes 576 for supportingthe cradle 572 from ceiling joists or an adjacent wall. Alternatively,an isolation spring (not illustrated in any of the figures) may besecured through each of the holes 576 and to an end of the threaded rod578 nearest the hole 576. The cradle 572 is also pierced by arectangularly-shaped hole 582 along an edge of the cradle 572 nearest tothe piping assemblies 202, 232. The hole 582 provides the cradle 572with a handle 584 for the zone-control unit 100 illustrated in FIG. 4similar to the handles 502 provided by the holes 512 depicted in FIG. 1that pierce the plates 506 a.

Galvanized or stainless steel sheet material forming the cradle 572includes linear, V-shaped troughs 586 formed therein in an X-shape whichextend between diagonal pairs of holes 576. The troughs 586 cause thecenter of the cradle 572 where the troughs 586 intersect to be thelowest point thereof. Consequently, any water leaking from the pipingassemblies 202, 232 collects at the middle of the cradle 572. The cradle572 preferably includes a threaded fitting (not illustrated in any ofthe figures) that is located at the intersection of the troughs 586. Thecradle 572 may have a flask (not illustrated in any of the figures)secured to the threaded fitting so any water which collects at themiddle of the cradle 572 may flow through the fitting and be collectedin the flask. Alternatively, a moisture sensor (not illustrated in anyof the figures) may be secured to the threaded fitting for sending anelectrical signal to a monitoring station if water collects at themiddle of the cradle 572.

Arranged in this way, the handle mounting brackets 504, plates 506 b andthe cradle 572 provide a structure for mechanically coupling themechanical terminal unit 102 and the piping assemblies 202, 232 togetherthereby reducing any possibility that the zone-control unit 100 might bedamaged while being transported from its assembly, test andqualification location to a construction site. Furthermore, the handle584 facilitates handling zone-control units 100 during theirinstallation into the HVAC system such as maneuvering zone-control units100 into position for installation into a building's ductwork. Duringinstallation, the handle mounting brackets 504, plates 506 b and thecradle 572 maintain positional relationships between the mechanicalterminal unit 102 including the coil 122 and the piping assemblies 202,232 because the handle mounting brackets 504, plates 506 b and thecradle 572 mechanically bind the entire zone-control unit 100 togetherinto a single unit.

FIG. 6 illustrates an alternative embodiment of the zone-control unit100 that further facilitates its installation into a building'sductwork. In this embodiment, a pair of sleeve mounting brackets 602,which replace the handle mounting brackets 504 depicted in FIG. 1,surround the casing 104 near opposite ends thereof. As betterillustrated in FIG. 7, each sleeve mounting bracket 602 includes asubstantially planar, generally rectangular frame 604 which extendsoutward from and surrounds the casing 104.

Stiffeners 606 a through 606 d, which may be formed integrally with theframe 604, project at right angles from interior edges 608 of the frame604 to extend respectively along sides of the casing 104.

Because each sleeve mounting bracket 602 replaces one handle mountingbracket 504 illustrated in FIG. 1, for the embodiment depicted in FIG. 6the handle 502 is secured to either one or the other of verticallyoriented sides 612 of the frame 604. Thus, the sleeve mounting bracket602 permits attaching handles 502 to either side of the frame 604 forsupporting the piping assemblies 202, 232.

A pair of hanging plates 616 respectively extend at right angles fromupper edges 614 of the vertically oriented sides 612 of the frame 604,and are preferably formed integrally with the sides 612. An aperture 622pierces each of the hanging plates 616 thereby adapting it to receiveone end of a threaded rod or of a seismic fastening product forsuspending the zone-control unit 100 when installed in a HVAC system.The sleeve mounting bracket 602 also includes a pair of reinforcingplates 626 each of which spans between a depending edge 628 of thehanging plates 616 and an upper edge 629 respectively of the stiffeners606 b and 606 d, and is welded thereto.

An elongated tab 632 projects upward as part of a horizontally orientedtop side 634 of the frame 604. Fasteners 642, such as sheet metalscrews, secure to the tab 632 a handle 644, which is shaped similar toor the same as the handle 502. Similar to the handle 502, as bestillustrated in FIG. 8 the handle 644 preferably includes a curved edge646. For suspending zone-control units 100 within a building using thehandle 644 secured to the tab 632 of the sleeve mounting bracket 602, anL-shaped upper mounting bracket 652 depicted in FIG. 7 is secured to ajoist or other building structural member. A handle 654 identical to thehandle 644 is secured to the upper mounting bracket 652 with fasteners656 such as sheet metal screws. As illustrated in FIG. 8, a curved edge658 of the handle 654 receives and mates with the curved edge 646 of thehandle 644. Configured in this way, the mated handles 644, 654 provide ahanger for suspending the zone-control unit 100 which seismicallyisolates the zone-control unit 100 from the building. Seismic andvibration insulation between the building and the zone-control unit 100can be enhanced by inserting between the curved edges 654, 658 a sheetof elastomeric material such as rubber (not illustrated in any of thefigures). The handles 644, 654 can also be further secured to each otherwith fasteners such as screws. While the curved edges 654, 658 arepreferred for coupling the handles 644, 654 together, other lockingmechanisms can be used such as clips or/and screws, or metal on metal,etc. If the zone-control unit 100 needs to be located further from thejoist or other structural member than that provided by the handles 644,654, appropriate lengths of sheet metal may be interposed between thetab 632 and the handle 644 and/or between the upper mounting bracket 652and the handle 654.

FIG. 9 illustrates yet another alternative embodiment of thezone-control unit 100 that further facilitates its installation into abuilding's ductwork. Analogously to the sleeve mounting bracket 602 ofFIGS. 6-8, in the embodiment of FIG. 9 four (4) columnar mountingbrackets 672 replace the handle mounting brackets 504 depicted inFIG. 1. Those elements depicted in FIG. 9 that are common to the sleevemounting bracket 602 illustrated in FIGS. 6-8 carry the same referencenumeral distinguished by a prime (“′”) designation. Comparing FIG. 9with FIGS. 6-8 reveals that each columnar mounting bracket 672 includesthe side 612′, the apertured hanging plate 616′, the reinforcing plate626 and either the stiffener 606 b′ or 606 d′ of the sleeve mountingbracket 602. Because each pair of columnar mounting brackets 672 lackthe top side 634 of the sleeve mounting bracket 602 with its tab 632 andthe handle 644 fastened thereto, when installed in a HVAC system thezone-control unit 100 illustrated in FIG. 9 must be hung from threadedrod or a seismic fastening product. The sleeve mounting brackets 602 andthe columnar mounting brackets 672 may be formed from 14 gauge sheetsteel.

Using 14 gauge sheet steel for the sleeve mounting brackets 602 and thecolumnar mounting brackets 672 may significantly increase the structuralrigidity the lighter 22 gauge sheet steel generally used in fabricatingthe casing 104 of the mechanical terminal unit 102. Thus, either thesleeve mounting brackets 602 or the columnar mounting brackets 672 maybe used advantageously in securing a zone-control unit 100 to a palletfor shipping to a building site. For example, either the sleeve mountingbrackets 602 or the columnar mounting brackets 672 may be appropriatelypierced by an aperture (not illustrated in any of the FIGS.) thatreceives strapping for securing the zone-control unit 100 to a pallet.Thus, both the sleeve mounting brackets 602 and the columnar mountingbrackets 672 facilitate shipping zone-control units 100 to a buildingsite without defects and/or damage.

FIG. 10 depicts an electrical components enclosure 702, analogous to theNEMA enclosure 552 depicted in FIG. 3, which may be included in azone-control unit 100 in accordance with the present disclosure that issuitable for installation only inside a building. Those elementsdepicted in FIG. 10 that are common to the zone-control unit 100depicted in FIG. 1 and to the NEMA enclosure 552 illustrated in FIG. 3carry the same reference numeral distinguished by a prime (“′”)designation. With respect to the casing 104 included in the zone-controlunit 100, the electrical components enclosure 702 may be secured to thetop, to the bottom or to the side of the casing 104 opposite to that onwhich the piping assemblies 202, 232 and handles 502 are located.

Differing from the on-off switch 562 that is located inside the NEMAenclosure 552 depicted in FIG. 3, the on-off switch 562′ illustrated inFIG. 10 and an associated LED power indicator 704 are both located in aseparate utility box 706 attached outside the electrical componentsenclosure 702. However, similar to the NEMA enclosure 552 depicted inFIG. 3, both the DDC controller 112′ and the transformer 564′ arelocated within the electrical components enclosure 702 depicted in FIG.10.

Including an individual transformer 564′ in each zone-control unit 100eliminates any need for an electrician to assemble multiple step downtransformers on an electrical panel, or to install 24 volt low voltagewiring between a remotely located transformer and a terminal unit asdescribed above. If the zone-control unit 100 is installed near a lightand power conduit within the building, supplying the zone-control unit100 with electrical power requires perhaps only a 1 to 5 foot connectionof electrical wire and/or conduit. Buildings equipped with newer lowenergy (high efficiency) lighting, require less electrical power thanthat required by prior, less efficient lighting. DDC controllers, suchas the DDC controller 112 and 112′ respectively depicted in FIGS. 3 and10, draw less than one-half (0.5) ampere of 115 volt alternating current(“AC”) electrical power. Therefore, the zone-control unit 100 can beconnected to a building's individual lighting circuits without a dangerof electrical overload.

Differing from the NEMA enclosure 552 depicted in FIG. 3, the utilitybox 706 may include a second on-off switch 712 and power outlet 714located in the utility box 706. The on-off switch 712 and the poweroutlet 714 provide a source of electrical power at the zone-control unit100 to be used when servicing the zone-control unit 100. The embodimentof the electrical components enclosure 702 depicted in FIG. 10 alsoincludes a service lamp 716 connected to an on-off switch 718. Analogousto the on-off switch 712 and the power outlet 714, the service lamp 716facilitates servicing the zone-control unit 100.

For the electrical components enclosure 702 depicted in FIG. 10,electrical wires 722 connect the on-off switch 562′ to the transformer564′ for energizing operation of the DDC controller 112′ with 115 voltalternating current (“AC”) electrical power. The electrical componentsenclosure 702 also preferably includes another set of electrical wires724 connected to the transformer 564′ which alternatively permitenergizing operation of the zone-control unit 100 with 277 volt ACelectrical power.

The electrical components enclosure 702 also preferably includes apressure sensor inlet 732 for receiving air from the HVAC system's ductsconnected to the zone-control unit 100. Within the electrical componentsenclosure 702, the pressure sensor inlet 732 supplies air from the ductsto the DDC controller 112′ via tubes 734. The electrical componentsenclosure 702 also includes a length of electrical wire 738 connected tothe DDC controller 112′ which facilitates connecting the zone-controlunit 100 to a temperature sensor located in the zone of the HVAC systemsupplied by the zone-control unit 100.

In general, DDC HVAC system controllers such as the DDC controller 112and 112′ respectively depicted in FIGS. 3 and 10 continually monitor andprovide individual zones with a supply of fresh air. Presently,conventional DDC controllers include a communication capability thatpermits a central computer to monitor a building's HVAC system'soperating status, and to coordinate operation of the various portions ofthe system including all of its terminal units. Presently, DDCcontrollers such as the 112 and 112′ respectively depicted in FIGS. 3and 10 are equipped with Local Area Network (“LAN”) communicationscapability. To facilitate installing the zone-control unit 100, asillustrated in FIG. 10 the electrical components enclosure 702 ispreferably equipped with a 100 ft. length of LAN cable 742 connected tothe DDC controller 112′. Establishing the LAN that interconnects groupsof zone-control units 100 all which include LAN cables 742 requires onlythat the LAN cable 742 of all but one of the zone-control units 100 inthe group be connected to another one of the group's zone-control units100.

To further facilitate installing zone-control units 100 into abuilding's HVAC system, FIG. 11 illustrates yet another alternativeembodiment of the zone-control unit 100 which replaces the caps 284 onthe piping assemblies 202, 232 with fittings 802 for connecting toflexible braided hoses 804 or other HVAC piping or hose components.Fittings 802 may be any type of fitting suitable for joining pipes,hoses, and the like. Fittings 802 may include press-fittings, pushfittings, and various kinds of solder-less fittings. Another valve 806connects to each end of the braided hoses 804 furthest from the pipingassemblies 202, 232. Similar to the caps 284, closing both valves 806connected to the end of each of the braided hoses 804 permitspressurizing both braided hoses 804, the piping assemblies 202, 232 andthe coil 122 for leak testing, the 24 hour pre-shipment qualificationpressure test, and assuring that the zone-control unit 100 remains leakfree until installed into ductwork of a building's HVAC system.

A copper tee plumbing fitting 808 may connect to each valve 806 on thebraided hoses 804 furthest from the piping assemblies 202, 232 on theside of the valves 806 furthest from the braided hoses 804. By includingthe tee plumbing fitting 808 in the zone-control unit 100, thisparticular embodiment permits a building's mechanical contractor, who isresponsible for its plumbing, to make straight runs of copper pipe forthe HVAC system's water which are located reasonably close to placeswhere zone-control units 100 are to be installed, e.g. within 2 feet.

Then when installing zone-control units 100 into the building'sductwork, rather than being required to plumb the HVAC system's pipingto the piping assemblies 202, 232, zone-control units 100 can beconnected with the HVAC system's piping by cutting out a small length ofthe previously plumbed piping, and inserting the tee plumbing fitting808 into the piping followed by sweating the connection of the teeplumbing fitting 808 to the HVAC system's piping.

FIG. 12A illustrates a side view of a zone-control unit 1000 for use inan HVAC system, according to one embodiment of the present invention,and FIG. 12B illustrates the corresponding end view. Zone-control unit1000 includes a duct or casing 1100, a thermal transfer unit 1200, aninlet piping assembly 1300, an outlet piping assembly 1400, and at leastone bracket 1500. In some embodiments, bracket 1500 can be apowder-coated handle shipping bracket. Bracket 1500 may include any of avariety of suitable materials, including metals, composites, and thelike. Inclusion of bracket 1500 can allow zone-control unit 1000 to bepre-engineered, sealed, pressure-tested, and shipped to job-site inworking condition, free of defects. Zone-control unit 1000 may includemilitary rubber Nitrile grommets 1510 for isolation between bracket 1500and piping assemblies 1300 and 1400. Grommets 1510 can help secure andprotect zone-control unit 1000, and can help reduce or eliminate thepossibility of galvanic corrosion at the interface between bracket 1500and piping assemblies 1300 and 1400. Grommets 1510 can be manufacturedto withstand heat, and in some cases can withstand a direct flame of 220degrees F., or higher. Bracket 1500 may include openings that aredesigned to fit the fork of a forklift, a steel pole, or a human hand.In some embodiments, bracket 1500 may not include an opening. Bracket1500 is well suited for reducing or preventing field damage. Forexample, with known systems and methods, field personnel typically liftor move HVAC components simply by grasping various piping or probeelements, which often results in destruction or serious damage to thecomponent. Bracket 1500 confers the ability to ship and maneuverzone-control unit 1000 in a standardized and safe manner. Often, thermaltransfer unit 1200, which may include a coil, is at least partiallydisposed within casing 1100. Inlet piping assembly 1300 is coupled withthermal transfer unit 1200 for supplying liquid or gas to coil 1200, andoutlet piping assembly 1400 is coupled with coil 1200 for receivingliquid or gas from coil 1200. This can be accomplished by coupling afirst passage 1310 of inlet piping assembly 1300 with a supply port 1210of thermal transfer unit 1200, and coupling a first passage 1410 of theoutlet piping assembly 1400 with a return port 1220 of thermal transferunit 1200. A second passage 1320 of inlet piping assembly 1300 can becoupled with an upstream fluid source 1330, and a second passage 1420 ofoutlet piping assembly 1400 can be coupled with a downstream fluiddestination 1430. In some embodiments, a portable piping structure mayinclude a heat exchanger coupled with a bracket and a pipe. The bracketis often also coupled with the pipe.

It is appreciated that inlet piping assembly second passage 1320 andoutlet piping assembly second passage 1420 each can be sealed, inletpiping assembly first passage 1310 can be in sealed communication withthermal transfer assembly supply port 1210, and outlet piping assemblyfirst passage 1410 can be in sealed communication with the thermaltransfer assembly return port 1220. When sealed in this fashion, thermaltransfer unit 1200 can contain a vacuum, a non-pressurized fluid, or apressurized fluid. Inlet piping assembly second passage 1320 and outletpiping assembly second passage 1420 can be manufactured from, forexample, ¾ inch type L copper water pipe. They can be sealed accordingto a heating and spinning procedure that introduces no annealing ordistortion of the pipe. After zone-control unit 1000 is placed in thedesired location relative to the HVAC system, distal tips of inletpiping assembly second passage 1320 and outlet piping assembly secondpassage 1420 can be cut, and connected with other HVAC piping or hoseelements, such as a hot water piping building loop. Relatedly,zone-control unit 1000 includes a pressure gauge 1710 coupled with inletpiping assembly 1400. In some embodiments, pressure gauge 1710 may becoupled with thermal transfer unit 1200 or outlet piping assembly 1300.Inlet piping assembly 1300 may be coupled with a drain valve 1330, aY-strainer 1340, a pressure/temperature port 1350, or a supply shutoffvalve 1360, or any combination thereof. Outlet piping assembly 1400 maybe coupled with control valve 1430, a balancing valve (not shown), avent (not shown), a pressure/temperature port 1450, or a return shutoffvalve 1460, or any combination thereof. Control valve 1430 may be anautomatic temperature control (ATC) valve having a compensated ballvalve including an integral pressure limiting and flow settingapparatus. Valve 1430 can assure consistent flow response regardless ofthe head pressure. In some cases, there is no CV setting on the valve.Relatedly, zone-control unit 1000 may include a field set manual orfactory programmable maximum flow setting. In some embodiments, valvebalancing may be accomplished in less than 30 seconds. Valve 1430 mayhave a shutoff pressure of 200 psi. Conveniently, valve 1430 may have apressure sufficient to counteract a heating loop dead head pressure,which can be 50 psi or more. In related embodiments, valve 1430 can be a½ inch, a ¾ inch, or 1 inch valve. Control valve 1430 may be amodulating Siemens ATC.

In some embodiments, a mechanical pressure/temperature port may bereplaced, supplemented, or operatively coupled with one or more analogor digital electronic sensors, including sensors enabled for wirelesscommunication, that detect or sense flow volume, for example in gallonsper minute (gpm), or other flow variables such as pressure, temperature,and the like. Advantageously, the incorporation of such electronicsensors can eliminate the need for a technician to manually access aheat exchanger to perform troubleshooting or diagnostic procedures withgauges. These electronic sensors can replace such gauges, and can bepre-calibrated or pre-programmed at a manufacturer factory prior toinstallation. Accordingly, many of all flow variables can be monitoredremotely through a building automation control system. A technician cancheck these variables remotely or wirelessly with a personal digitalassistant (PDA), a laptop, or other suitable device. These sensors mayalso be operatively coupled with a damper assembly controller, a directdigital controller, an analog electronic controller, or other desiredcomponent of a zone-control unit.

Thermal transfer unit 1200 may be coupled with a vent 1230 such as anair vent. In some instances, vent 1230 is a manual air vent disposed ator toward the highest point of thermal transfer unit 1200. Vent 1230 canhelp ensure proper drainage of air or other unwanted fluids or gassesthat enter the system, which can have deleterious effects on an HVACsystem. For example, unwanted air in a hot water system can causecavitation in a hot water pump, which may cause malfunction ordestruction of the pump or other system components. Vents can also helpensure optimum flow characteristics when draining thermal transfer unit1200 or other zone-control unit 1000 components. Full drainage of suchcomponents can facilitate the removal of unwanted particles such as rustor other chemical buildup. In some embodiments, vent 1230 is constructedof a non-corrosive military grade brass. In the embodiment shown here,zone-control unit 1000 includes a duct interface 1110 which iscoupleable with duct or casing 1100, which may be attached with orintegral to a duct or ductwork of an HVAC system. Bracket 1500, whichmay include a handle, supports duct interface 1100, inlet pipingassembly 1300, and outlet piping assembly 1400 with relative positionsappropriate for use in an HVAC system or other climate control system.In some cases, bracket 1500 may be a handle configured to maintain ductor casing 1100, inlet piping assembly 1300, and outlet piping assembly1400 in positional relationship.

As shown in FIG. 12A, zone-control unit 1000 can include a damperassembly controller 1600, which may be coupled with casing 1100. Damperassembly controller 1600 may be configured to receive a signal from athermostat or a room sensor (not shown). In some embodiments, damperassembly controller 1600 can include, for example, an analog electroniccontroller, or a direct digital control (DDC) controller equipped withLocal Area Network (LAN) communication capability. In some cases,controller 1600 can be a pneumatic DDC. Controller 1600 can also beconfigured to operatively associate with or have connectivity with aLonWorks or BACnet system. Unit 1000 can also include an automatictemperature control (ATC) valve 1430, which is typically coupled with orpart of outlet piping assembly 1400, and configured to receive a signalfrom damper assembly controller 1600, for example, by connection withplenum rated actuator wires 1432. Other embodiments may employ wirelesssignal transmission technologies. In certain embodiments, ATC valve 1430is a Nema 1 24V Belimo proportional actuator. Accordingly, in someembodiments the present invention provides a proportional hot watervalve package (PICCV). Often, zone-control unit 1000 will be configuredto have one piping interface, one electrical interface, and one sheetmetal interface, so as to provide a “plug and play” unit for ease ofshipping and installation.

FIG. 13A illustrates a side view of a zone-control unit 2000 for use inan HVAC system, according to one embodiment of the present invention,and FIG. 13B illustrates the corresponding end view. Zone-control unit2000 includes a duct or casing 2100, a thermal transfer unit 2200, aninlet piping assembly 2300, an outlet piping assembly 2400, and at leastone bracket 2500. Often, thermal transfer unit 2200, which may include acoil, is at least partially disposed within casing 2100. Inlet pipingassembly 2300 is coupled with thermal transfer unit 2200 for supplyingliquid or gas to coil 2200, and outlet piping assembly 2400 is coupledwith coil 2200 for receiving liquid or gas from coil 2200. This can beaccomplished by coupling a first passage 2310 of inlet piping assembly2300 with a supply port 2210 of thermal transfer unit 2200, and couplinga first passage 2410 of the outlet piping assembly 2400 with a returnport 2220 of thermal transfer unit 2200. A second passage 2320 of inletpiping assembly 2300 can be coupled with an upstream fluid source 2330,and a second passage 2420 of outlet piping assembly 2400 can be coupledwith a downstream fluid destination 2430.

It is appreciated that inlet piping assembly second passage 2320 andoutlet piping assembly second passage 2420 each can be sealed, inletpiping assembly first passage 2310 can be in sealed communication withthermal transfer assembly supply port 2210, and outlet piping assemblyfirst passage 2410 can be in sealed communication with the thermaltransfer assembly return port 2220. When sealed in this fashion, thermaltransfer unit 2200 can contain a vacuum, a non-pressurized fluid, or apressurized fluid. Relatedly, zone-control unit 2000 includes a pressuregauge 2710 coupled with inlet piping assembly 2400. In some embodiments,pressure gauge 2710 may be coupled with thermal transfer unit 2200 orinlet piping assembly 2300. Inlet piping assembly 2300 may be coupledwith a drain valve 2330, a Y-strainer 2340, a pressure/temperature port2350, or a supply shutoff valve 2360, or any combination thereof. Outletpiping assembly 2400 may be coupled with control valve 2430, a manualbalancing valve 2470, a vent (not shown), a pressure/temperature port2450 disposed upstream of control valve 2430, a pressure/temperatureport 2452 disposed downstream of control valve 2430, or a return shutoffvalve 2460, or any combination thereof. In some cases, balancing valve2470 may be a Griswold pressure independent balancing valve. Thermaltransfer unit 2200 may be coupled with a vent 2230 such as an air vent.In the embodiment shown here, zone-control unit 2000 includes a ductinterface 2110 which is coupleable with duct or casing 2100, which maybe attached with or integral to a duct or ductwork of an HVAC system.Bracket 2500, which may include a handle, supports duct interface 2110,inlet piping assembly 2300, and outlet piping assembly 2400 withrelative positions appropriate for use in an HVAC system or otherclimate control system. In some cases, bracket 2500 may be a handleconfigured to maintain duct or casing 2100, inlet piping assembly 2300,and outlet piping assembly 2400 in positional relationship.

As shown in FIG. 13A, zone-control unit 2000 can include a damperassembly controller 2600, which may be coupled with casing 2100. Damperassembly controller 1600 may be configured to receive a signal from athermostat or a room sensor (not shown). In some embodiments, damperassembly controller 2600 includes a direct digital control (DDC)controller equipped with Local Area Network (LAN) communicationcapability. Unit 2000 can also include an automatic temperature control(ATC) valve 2430, which is typically coupled with or part of outletpiping assembly 2400, and configured to receive a signal from damperassembly controller 2600, in some embodiments by connection with plenumrated actuator wires 2432, via wireless signal transmission systems, orthe like. In certain embodiments, ATC valve 2430 is a Nema 1 24V Belimoon/off actuator. Accordingly, in some embodiments the present inventionprovides a two way water valve package (CCV).

FIG. 14A illustrates a side view of a zone-control unit 3000 for use inan HVAC system, according to one embodiment of the present invention,and FIG. 14B illustrates the corresponding end view. Zone-control unit3000 includes a duct or casing 3100, a thermal transfer unit 3200, aninlet piping assembly 3300, an outlet piping assembly 3400, a bypasspiping assembly 3800, and at least one bracket 3500. Often, thermaltransfer unit 3200, which may include a coil, is at least partiallydisposed within casing 3100. Inlet piping assembly 3300 is coupled withthermal transfer unit 3200 for supplying liquid or gas to coil 3200, andoutlet piping assembly 3400 is coupled with coil 3200 for receivingliquid or gas from coil 3200. This can be accomplished by coupling afirst passage 3310 of inlet piping assembly 3300 with a supply port 3210of thermal transfer unit 3200, and coupling a first passage 3410 of theoutlet piping assembly 3400 with a return port 3220 of thermal transferunit 3200. A second passage 3320 of inlet piping assembly 3300 can becoupled with an upstream fluid source 3330, and a second passage 3420 ofoutlet piping assembly 3400 can be coupled with a downstream fluiddestination 3430.

It is appreciated that inlet piping assembly second passage 3320 andoutlet piping assembly second passage 3420 each can be sealed, inletpiping assembly first passage 3310 can be in sealed communication withthermal transfer assembly supply port 3210, and outlet piping assemblyfirst passage 3410 can be in sealed communication with the thermaltransfer assembly return port 3220. Similarly, bypass piping assembly3800 can be in sealed communication with inlet piping assembly 3300 andoutlet piping assembly 3400 so as to provide a fluid passagetherebetween, whereby the passage can be open and closed via operationof bypass shutoff valve 3810. When sealed in this fashion, thermaltransfer unit 3200 can contain a vacuum, a non-pressurized fluid, or apressurized fluid. Relatedly, zone-control unit 3000 includes a pressuregauge 3710 coupled with outlet piping assembly 3400. In someembodiments, pressure gauge 3710 may be coupled with thermal transferunit 3200 or inlet piping assembly 3300. When bypass shutoff valve 3810is in the open position, fluid can flow directly from inlet pipingassembly 3300 to outlet piping assembly 3400 without flowing throughthermal transfer unit 3200. When bypass shutoff valve 3810 is in theclosed position, fluid can flow from inlet piping assembly 3300 tooutlet piping assembly 3400 through thermal transfer unit 3200, withoutflowing through bypass piping assembly 3800. Inlet piping assembly 3300may be coupled with a drain valve 3330, a Y-strainer 3340, apressure/temperature port 3350, or a supply shutoff valve 3360, or anycombination thereof. Outlet piping assembly 3400 may be coupled withcontrol valve 3430, a manual balancing valve 3470, a vent (not shown), apressure/temperature port 3450 disposed upstream of control valve 3430,a pressure/temperature port 3452 disposed downstream of control valve3430, or a return shutoff valve 3460, or any combination thereof.Thermal transfer unit 3200 may be coupled with a vent 3230 such as anair vent. In the embodiment shown here, zone-control unit 3000 includesa duct interface 3110 which is coupleable with duct or casing 3100,which may be attached with or integral to a duct or ductwork of an HVACsystem. Bracket 3500, which may include a handle, supports ductinterface 3110, inlet piping assembly 3300, and outlet piping assembly3400 with relative positions appropriate for use in an HVAC system orother climate control system. In some cases, bracket 3500 may be ahandle configured to maintain duct or casing 3100, inlet piping assembly3300, and outlet piping assembly 3400 in positional relationship.

As shown in FIG. 14A, zone-control unit 3000 can include a damperassembly controller 3600, which may be coupled with casing 3100. Damperassembly controller 3600 may be configured to receive a signal from athermostat or a room sensor (not shown). In some embodiments, damperassembly controller 3600 includes a direct digital control (DDC)controller equipped with Local Area Network (LAN) communicationcapability. Unit 3000 can also include an automatic temperature control(ATC) valve 3430, which is typically coupled with or part of outletpiping assembly 3400, and configured to receive a signal from damperassembly controller 3600 by connection with plenum rated actuator wires3432, wireless transmission systems, or the like. In certainembodiments, ATC valve 3430 is a Nema 1 24V Belimo three way actuator.Accordingly, in some embodiments the present invention provides a threeway water valve package (CCV).

FIG. 15 illustrates a side view of a zone-control unit 4000 for use inan HVAC system, according to one embodiment of the present invention.Zone-control unit 4000 includes a duct or casing 4100, a thermaltransfer unit 4200, an inlet piping assembly 4300, an outlet pipingassembly 4400, and at least one bracket 4500. Often, thermal transferunit 4200, which may include a coil, is at least partially disposedwithin casing 4100. Inlet piping assembly 4300 is coupled with thermaltransfer unit 4200 for supplying liquid or gas to coil 4200, and outletpiping assembly 4400 is coupled with coil 4200 for receiving liquid orgas from coil 4200. Zone-control unit 4000 includes a pressure gauge4710 coupled with outlet piping assembly 4400. In some embodiments,pressure gauge 4710 may be coupled with thermal transfer unit 4200 orinlet piping assembly 4300. Inlet piping assembly 4300 may be coupledwith a basket strainer 4380. Zone-control unit 4000 can be cleaned byfluid or water pressure without removing basket strainer 4380. Inletpiping assembly may also be coupled with a blow down drain 4370 forbasket strainer 4380. Outlet piping assembly 4400 may be coupled with acontrol valve 4430. In the embodiment shown here, zone-control unit 4000includes a casing 4100 which may be attached with a duct or ductwork ofan HVAC system. Bracket 4500, which may include a handle, supportscasing 4100, inlet piping assembly 4300, and outlet piping assembly 4400with relative positions appropriate for use in an HVAC system or otherclimate control system. Zone-control unit 4000 may also include a customdigital imaging tag 4130 or custom PC router tag or validation package4120 containing information regarding the configuration or manufactureof the unit. Information may be provided in electronic or paper format,and may include submittal information, O&M's of unit components, digitalpictures of the product or components, QC sheets, wiring and pipingdiagrams, parts lists with model numbers and serial numbers, and thelike.

FIG. 16 illustrates a side view of a zone-control unit 5000 for use inan HVAC system, according to one embodiment of the present invention.Zone-control unit 5000 includes a duct or casing 5100, a thermaltransfer unit (not shown), an inlet piping assembly 5300, an outletpiping assembly 5400, and at least one bracket 5500. Zone-control unit5000 also includes a housing 5900 coupled with casing 5100, such thathousing 5900 encompasses ATC valve (not shown) and other components ofzone-control unit 5000 as described elsewhere herein. For comparativereference with other figures of the present disclosure, zone-controlunit 5000 is depicted here showing a vent 5230, a drain valve 5330, aninlet piping assembly second passage 5320 and an outlet piping assemblysecond passage 5420. A housing cover 5910 of housing 5900 may have anaperture 5920 through which bracket 5500 may extend, or through whichbracket 5500 may be otherwise accessible via an operator's hands, aforklift, or other maneuvering apparatus used during transportation,shipping, or installation. Zone-control unit 5000 may also have avalidation package 4120, which may include a digital picture of thezone-control unit 5000 or components thereof, a quality control sheet,an operations and maintenance document, a parts list with model andserial numbers, an Indoor Air Quality (IAQ) certification, or a piping,electrical, and controls schematic, or any combination thereof. Thesecomponents of validation package 4120 may be stored in a plastic pouchand attached with unit 6000. It is appreciated therefore that thepresent invention can be conveniently tested, validated, standardized,cataloged, and certified prior to shipping or installation.

FIG. 17 illustrates a side view of a zone-control unit 6000 for use inan HVAC system, according to one embodiment of the present invention. Inmany ways, the embodiment shown in FIG. 17 is similar to that shown inFIG. 16. Zone-control unit 6000 includes a duct or casing 6100, an inletpiping assembly 6300, an outlet piping assembly 6400, and at least onebracket 6500. Zone-control unit 6000 also includes a housing 6900coupled with casing 6100, such that housing 6900 encompasses variouscomponents of zone-control unit 6000 as described elsewhere herein, andto avoid prolixity are not described in detail here. The zone-controlunit 6000 embodiment shown in FIG. 17 differs from the zone-control unit5000 shown in FIG. 16, however, in a housing cover (not shown) ofzone-control unit 6000 is removed, thereby exposing various elementscontained in housing 6900. In some embodiments, the zone-control unitcomplies with a standard such as a Leadership in Energy andEnvironmental Design (LEED) standard, an American Society of Heating,Refrigerating, and Air Conditioning Engineers (ASHRAE) standard, anAir-Conditioning and Refrigeration Institute (ARI) standard, or abuilding code standard, or any combination thereof. Zone-control unit6000 may be a capital piece of equipment, depreciable, and can bestocked by local distributors anywhere in the world as an “off theshelf” product. Zone-control unit 6000 is well suited for installationin a new HVAC system, or for retrofit in an existing HVAC system. It isalso appreciated that the present invention also provides for themanufacture and installation of the zone-control units discussed herein.Such manufacture will often occur remotely from a job installation site,and may be performed by a union member selected from the groupconsisting of the United Association of Journeymen and Apprentices ofthe Plumbing and Pipefitting Industry of the United States and Canada,the construction sheet metal union, and the electrical union. In otherembodiments, such union(s) may certify the fabrication site and/orsupplier as being in compliance with the applicable union rules, thatuse of certain catalogued HVAC units complies with applicable unionrequirements and/or does not constitute a customized product so asviolate work preservation rules. Relatedly, zone-control units orcomponents thereof may be constructed by a manufacturing facility thatis a signatory to any of these unions. Such manufacturing facilities mayalso have an Underwriter's Laboratory certification. Accordingly,zone-control units may include or be affixed with certain union,standards, or certification compliance labels.

FIGS. 18A-18E illustrate a heat exchanger coil 7000 packaged withcomponents similar to those described above, with some or all of thecomponents supported by support structures or handles. The heatexchanger coil, piping, valves, and/or valve controllers may bepre-assembled prior to shipping to a construction job site, with some orall of the assembly optionally being performed using robotic fabricationtechniques and systems. The support structures or handles can facilitatehandling and installation of the assembled unit, protect the unit andcomponents thereof during shipping, and may also be used to support theunit after installation. The piping may terminate with sealed pipingstubs during shipping and installation, with a pressure sensor and gaugeallowing quick verification of the piping assembly integrity. Along withheat exchanger/coil units, other HVAC units such as fan coil units andthe like may benefit from the systems and methods described herein.Standardization, quality control and tracking, and other improvedstructures and method described herein may also be implemented with suchunits.

FIGS. 19A-19B generally illustrate standardization of components indiffering HVAC units. Rather than attempting to minimize the costs ofindividual components of the many HVAC units in an HVAC system (whichcan lead to extensive on-site work, delays, and large installation laborcosts), overall system installation efficiencies can be enhanced throughthe use of more standardized components, even if those components havecapacities that exceed the requirements of some units.

Proportional valves (including those having characteristics similar tothose graphically illustrated in FIG. 19A, such as the Belimo™ PICCVpressure independent proportional ball valve) and the like canfacilitate integration of a single type of HVAC unit in multiplelocations having differing specifications, tailoring the functioning ofthe unit by though appropriate use of the electronic controllersoftware. FIG. 19B illustrates an HVAC hot water coil piping packageunit 8000, while FIGS. 12A and 13A illustrate an HVAC proportional hotwater valve package unit and a 2 way water valve package unit,respectively. FIG. 12B illustrates a support structure or handle whichmay be used in both, and FIG. 14A illustrates a 3 way water valvepackage unit. Despite the significant differences between these units,many, most, or all of the components (including piping components) maybe common, with the aspect ratio of the piping optionally beingidentical. In some embodiments, zone-control units or heat exchanges canhave pipe components with dimensions or configurations that arestandardized or customized. For example, zone-control units can bemanufactured to provide spun copper caps that are of a standard lengthor dimension, and that are oriented in a standard direction. Relatedly,zone-control units can be manufactured to provide piping assemblies,pipes, and other piping aspects that conform with a prescribedspecification. In some cases, pipe components such as piping assembliesor end caps can have equal or otherwise prescribed lengths. Similarly,zone-control units can be configured so as to provide a standardized orcustomized distance between the piping assemblies of a single unit.Accordingly, sets of two or more zone-control units can be manufacturedaccording to certain piping component specifications (e.g. length,dimension, orientation, and the like). Such standardization orcustomization can be applied to any of a variety of sizes andconfigurations of zone-control units or heat exchangers, and can provideheretofore unrecognized advantages and efficiencies in buildingconstruction and repair. For example, multiple zone-control units, eachhaving a different size and configuration, can be manufactured having astandardized distance between piping assemblies or end caps.

FIG. 20 illustrates engagement between the support structure or handle9000 mounted to an HVAC unit and another similar corresponding supportstructure, allowing the support structures to be used as mountingfasteners. A plurality of different configurations of support structurescan be provided with different sizes, different numbers, sizes, andconfigurations of holes and grommets for receiving piping, and the like.One or more supports may be secured to a joist, beam, or other buildingstructure where the HVAC unit is to be installed. The unit supportstructure or handle is then lifted into engagement with the securedsupport(s), and the engaging surface at least temporarily “hanging” ormaintaining the position of the HVAC unit. Fasteners may then affix thecorresponding engaged support structures together to provide a secureand/or permanent installation. Deformable damping materials such asrubber, neoprene, resilient polymers, or the like along one or both ofthe engaging support surfaces can provide vibration and/or soundisolation. The support structures or handles may comprise carbon fiber,stainless steel, aluminum, plastic, or the like, and the engagingsupport structures may have similar shapes (as shown) or differentshapes.

FIGS. 21A and 21B illustrate methods for testing and validation of HVACunits. HVAC units. Unit ordering and fabrication can be automated, andtesting of piping by pressurizing piping assemblies, sealing, andverifying an acceptable pressure is maintained after a test period (forexample, 24 hours) ensures leak-free fabrication. Any re-work can beidentified and completed prior to shipping to a constructions site, andquality control documentation (optionally comprising a magnetic mediasuch as a floppy disk, an optical media such as a mini CD, a memory suchas a flash memory stick, or some other tangible media embodying machinereadable computer data, a print-out, a digital photograph, and/or thelike) can be associated with each unit to validate the components andtesting. In some embodiments, such quality control may be integratedinto the HVAC signal transmission system so as to facilitate remotevalidation via LAN conductors or a wireless network system, and/orradiofrequency identification or RFID techniques and structures may beemployed.

FIG. 22 shows a control assembly 22000 for an HVAC system according toone embodiment of the present invention. Control assembly 22000 includesa controller 22100, a LAN 22200, a front end computer software 22300, aremote monitoring component 2240, and a thermostat or room sensor 22700.Control assembly 22000 may also receive a variety of inputs 22500 from,and transmit a variety of outputs 22600 to, a zone control unit or otherHVAC component such as a proportional hot water valve package (PICCV), atwo way water valve package (CCV), and the like. In some cases, controlassembly 22000 can be in operative association with, for example, afactory precalibrated self balancing zone control unit or heatexchanger. Zone control units can include pressure/temperature ports,discharge air sensors, analog or digital pressure gauges, temperatureresistors, and the like which can provide input to controller 22100.Similarly, controller 22100 can provide output to various components ofa zone control unit, such as proportional actuators. Theseinterconnectivities can allow a zone control unit to regulate pressureautomatically. In some cases, a thermostat or room sensor 22700 may havea setpoint, and contain a digital display for showing pressure, gpm,space temperature, leaving air temperature, setpoint, and the like.Often these attributes or aspects thereof are transmitted fromcontroller 22100 to thermostat 22700. Relatedly, room temperature,setpoints, and other variables can be transmitted from thermostat 22700to controller 22100. Connectivity between various components of controlassembly 22000, and between components of control assembly 22000 andother HVAC components, can be hardwired, wireless, or a combinationthereof.

In one embodiment, a zone control unit includes a Belimo PICCV pressureindependent automatic control valve or other pressure independentbalancing valve on a heat exchanger such that water field balancing iseliminated or reduced. Components and sensors can be pre-calibrated atthe factory. A sensor can be mounted in a plenum near the heat exchangerthat senses leaving air temperature, pressure, and other variables. Theplenum can be added at the factory. A room sensor or thermostat can bemounted in a desired room or zone. Controllers such as a DDC controllercan be used with this system, and can be mounted, wired andpre-programmed at the factory. The controller can take inputs from thevarious sensors that are pre-wired to the controller at the factory. Anexemplary sequence of operation can be described as follows. Thetemperature in the room is 70° F. and the occupant wishes to raise thetemperature to 72° F. by adjusting the room sensor or thermostat to thedesired set point. That signal is sent to the DDC controller. Theleaving air temperature sensor senses or reads 70° F. at a heatexchanger discharge, and provides an input signal to the DDC controller.The DDC controller processes the two inputs: the room sensor and theleaving air sensor. The controller then sends a signal to the actuatoron the automatic temperature control (ATC) valve actuator to open thevalve and increase the gpm flow to heat exchanger coil thus raising theleaving air temperature (LAT) to an effective set point (e.g. 74° F.)until the room sensor measures the room air at 72° F. A balancing valvecan be pressure independent and set at the factory so as to maintain agpm regardless of pressure. In some cases, if more flow or hotter wateris needed, a controller can send signals to a computer with front endsoftware, and the computer can send signals to pumps or a boiler toadjust the temperature or gpm. Once the room sensor measures the desiredset point, the controller closes the ATC valve thus limiting thegpm/flow through the heat exchanger device and maintaining the desiredset point to extreme or programmed tolerances. This sequence ofoperation can occur every second. If the room temperature sways in anydirection by even 0.01° F. or less, the LAT temperature can be adjustedimmediately at the heat exchanger to maintain the desired heatexchanger. This process can save significant amounts of energy, cancontrol the space temperature precisely, can provide for better indoorair quality, and can qualify the system for LEED building points/Greenbuilding initiative. Furthermore, the entire water side of the systemcan be completely self balancing. The need for technicians to go to thejob site and balance, calibrate, take readings, and the like can beeliminated or reduced. Regulation can be accomplished through thebuilding automation control system and can be self correctingautomatically. This can be accomplished by providing a portable pipingstructure on the heat exchanger, which confers the ability to ship theheat exchanger with the portable piping structure attached, withoutincurring damage. By doing this, it is possible to add these featuresand benefits, including pre-calibration and pre-programming, to theportable piping structure of the heat exchanger on a cost effectivebasis, and also to associated products into which heat exchangers areinstalled. Similarly, it is possible to add these features and benefitsto stand alone heat exchangers.

These approaches are well suited for a variety of environments,including biotech laboratories, clean rooms, offices, and the like.These techniques can provide for constant, realtime adjustments tomaintain desired setpoints. Embodiments disclosed herein can be used toreplace or reduce the need for manual balancing, and can modulate ATCvalves to keep gpm appropriately adjusted.

FIG. 23 shows an embodiment of a zone control unit or heat exchangersmart control configuration 23000. Configurations such as these can beused for one or more zones or products. A controller 23100, whichoptionally includes a read out or display, receives input from liquidsensors 23200 such as flow sensors, pressure sensors, and the like.Controller 23100 also receives input from air sensors 23300 such asleaving air temperature sensors, pressure sensors, and the like.Controller 23100 can provide output to an air damper actuator 23400, aliquid valve actuator 23500, or other zone control unit or heatexchanger component. Controller 23100 may also receive data from, andtransmit data to, a LAN, which may be in operative association with oneor more controllers 23700 of other devices in the building, and with acomputer 23800 containing operational software. Controller 23100 mayalso receive data from, and transmit data to, a thermostat 23900 with aroom sensor and a setpoint adjustment with read out. Thermostat 23900can display any parameter of a zone control unit or heat exchangerincluding flows, temperatures, pressures, and the like. Similarly,thermostat 23900 can display all data transmitted between controller23100 and thermostat 23900. A technician can trouble shoot thisconfiguration via readouts from thermostat 23900, controller 23100, orother components. In some embodiments, a technician can trouble shootfrom a wireless PDA which is in operative association with one or morecomponents of configuration 23000. Any parameter of configuration 23000can be set at a manufacturer's factory and can be pre-calibrated. Forexample, air and water balancing and calibration can be done at thefactory. Thereafter, any air and water balancing changes in the fieldcan be accomplished via a computer which may be remotely linked with theconfiguration. In this way, a system can be self-balancing and energyefficient. Moreover, the system exhibits improved indoor air quality(IAQ) control, comfort, and response time.

Table 1 shows an example of a PICCV pressure independent ATC valve threepoint floating with ninety second stroke time values.

TABLE 1 Range Setpoint Actual Value Open ° F. Stroke Time .1-2 72 71 110% 75  9 70 2 20% 80  9 69 3 30% 85  9 68 4 40% 90  9 67 5 50% 95 45second stroke time 66 6 60% 100  9 65 7 70% 105  9 64 8 80% 110  9 63 990% 115  9 62 10 100%  120 90 seconds full open

FIG. 24 shows graph of a front end mathematical calculation or algorithmbased on desired performance and time values. Units can be accordinglybench tested and pre-calibrated and balanced at the factory.

Although zone control units, thermal transfer units, and other elementsof environmental control systems discussed herein are often referred toin terms of HVAC units, it is appreciated that such zone control units,thermal transfer units, and the like may find use in any of a variety ofcontrol systems. Moreover, although transfer units are often describedas, for example, coil structures, embodiments encompassed herein includeany of a variety of transfer unit or control unit configurations. Pipingstructures and configurations disclosed herein can be used in any of avariety of heat exchanger devices, systems, or methods.

Although the present invention has been described in terms of thepresently preferred embodiment, it is to be understood that suchdisclosure is purely illustrative and is not to be interpreted aslimiting. Consequently, without departing from the spirit and scope ofthe invention, various alterations, modifications, and/or alternativeapplications of the invention will, no doubt, be suggested to thoseskilled in the art after having read the preceding disclosure.Accordingly, it is intended that the following claims be interpreted asencompassing all alterations, modifications, or alternative applicationsas fall within the true spirit and scope of the invention.

What is claimed is:
 1. A zone-control unit for use in a climate controlsystem, the zone-control unit comprising: a casing; a thermal transferassembly at least partially disposed within the casing, the thermaltransfer assembly having a supply port and a return port; an inletpiping assembly for supplying fluid to the thermal transfer assembly,the inlet piping assembly having a first passage coupled with thethermal transfer assembly supply port and a second passage coupleablewith an upstream fluid source, wherein at least a portion of the inletpiping assembly is disposed exterior to the casing; an outlet pipingassembly for receiving fluid from the thermal transfer assembly, theoutlet piping assembly having a first passage coupled with the thermaltransfer assembly return port and a second passage coupleable with adownstream fluid destination, wherein at least a portion of the outletpiping assembly is disposed exterior to the casing; a duct interfacecoupled with the casing; a bracket supporting the duct interface, theinlet piping assembly, and the outlet piping assembly with relativepositions appropriate for use in the climate control system, wherein atleast a portion of the bracket is disposed exterior to the casing; and adamper assembly controller coupled with the casing, the damper assemblycontroller configured to receive a signal from a thermostat or a roomsensor.
 2. The zone-control unit according to claim 1, wherein the inletpiping assembly second passage and the outlet piping assembly secondpassage are each sealed, the inlet piping assembly first passage is insealed communication with the thermal transfer assembly supply port, andthe outlet piping assembly first passage is in sealed communication withthe thermal transfer assembly return port.
 3. The zone-control unitaccording to claim 1, wherein the thermal transfer unit contains avacuum, a non-pressurized fluid, or a pressurized fluid.
 4. Thezone-control unit according to claim 1, further comprising a pressuregauge coupled with a member selected from the group consisting of thethermal transfer assembly, the inlet piping assembly, and the outletpiping assembly.
 5. A zone-control unit for use in a climate controlsystem, the zone-control unit comprising: a thermal transfer assemblyhaving a supply port and a return port; an inlet piping assembly havinga first passage coupled with the thermal transfer assembly supply portand a second passage coupleable with an upstream fluid source; an outletpiping assembly having a first passage coupled with the thermal transferassembly return port and a second passage coupleable with a downstreamfluid destination; a duct interface; and a bracket supporting the ductinterface, the inlet piping assembly, and the outlet piping assemblywith relative positions appropriate for use in the climate controlsystem.
 6. The zone-control unit according to claim 5, wherein the inletpiping assembly second passage and the outlet piping assembly secondpassage are each sealed, the inlet piping assembly first passage is insealed communication with the thermal transfer assembly supply port, andthe outlet piping assembly first passage is in sealed communication withthe thermal transfer assembly return port.
 7. The zone-control unitaccording to claim 6, wherein the thermal transfer unit contains avacuum, a non-pressurized fluid, or a pressurized fluid.
 8. Thezone-control unit according to claim 5, further comprising a pressuregauge coupled with a member selected from the group consisting of thethermal transfer assembly, the inlet piping assembly, and the outletpiping assembly.
 9. The zone-control unit according to claim 5, whereinthe inlet piping assembly is coupled with a member selected from thegroup consisting of a drain, a strainer, a pressure gauge, apressure/temperature port, and a supply shutoff valve.
 10. Thezone-control unit according to claim 5, wherein the outlet pipingassembly is coupled with a member selected from the group consisting ofa control valve, a balancing valve, a vent, a pressure gauge, apressure/temperature port, and a return shutoff valve.
 11. Thezone-control unit according to claim 5, wherein the duct interface iscoupleable with a duct of the climate control system, such that the ducthouses at least a portion of the thermal transfer unit.
 12. Thezone-control unit according to claim 5, further comprising a bypasspiping assembly coupling the inlet piping assembly with the outletpiping assembly.
 13. The zone-control unit according to claim 5, whereinthe zone-control unit complies with a standard selected from the groupconsisting of a Leadership in Energy and Environmental Design (LEED)standard, an American Society of Heating, Refrigerating, and AirConditioning Engineers (ASHRAE) standard, an Air-Conditioning andRefrigeration Institute (ARI) standard, and a building code standard.14. The zone-control unit according to claim 5, wherein at least one ofthe inlet piping second passage or the outlet piping second passage iscoupled with a hose via a press-fitting joint.
 15. The zone-control unitaccording to claim 14, wherein the press-fitting joint complies with anapplicable standard.
 16. The zone-control unit according to claim 15,further comprising a validation package comprising a member selectedfrom the group consisting of a digital picture of the zone-control unit,a completed quality control sheet, an operations and maintenancedocument, a parts list with model number, an Indoor Air Quality (IAQ)certification, and a piping, electrical, and controls schematic.